Lean Operations and Lean Manufacturing

1. Lean Operations
Lean and Not Mean
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2. Vision
• Prepare your Mind
– An Open Mind is Powerful
• Do not Limit it to the boundaries of Previous
Experiences
• You may not get there, but try – others
certainly will !
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3. Lean
• A Journey of Continuous Improvement
– Not Sequential
– Not a “One Off” Procedure
• It Maximises Customer Satisfaction
• It Eliminates Waste
– Cost of Sales
• Provides An Environment for Business
GROWTH
– Start Out Today !
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4. Lean
• The STEPS
– Value
– Opposite to Waste
– Value Stream
– Process Mapping (Best Practices)
– FLOW
– Continuous and Seamless
– PULL
– On Demand
– Quality-Cost-Delivery
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5. Value
• Specify VALUE from the point of view of
the Customer
– Customers buy results not Products
• 20/20 vision, not Glasses
• A clean Shirt, not a washing Machine
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6. Value
• Value is Opposite to Waste
• Eleven Types of Waste
» Overproduction
» Waiting
» Transporting
» Inappropriate processing
» Unnecessary Inventory
» Unnecessary Movement
» Unnecessary Defects
» Untapped Human Potential
» Inappropriate Systems
» Energy and Water
» Pollution Waste
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7. Value Stream
• Value Stream – Sequence of Processes
– Define Process
• Best Practices
– Analyse Process
• Mystery Shopper
– Control Process
• Visual Indicator
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8. Value Stream
• Process – Best Practices
– Raw Material Process to Final Customer
• Supply Chain
• Design Glasses
• Manufacture Glasses
• Collections
• Adjust and Fit
• Sales
• Satisfied Customer
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9. FLOW
• Make Value Flow
• One Piece flow
• Keep it moving
• Minimise Batch and Queue
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10. PULL
• Only Make as Needed
• Pull according to Customer Demand
• Pull Reduces Time and Waste
• Do not Overproduce
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11. Quality-Cost-Delivery
• Quality
– Producing Exactly what the Customer Wants
with Zero Waste
• Cost
– Fair Price – Zero Waste
– Value for Money
• Delivery
– Not Too Early / Not Too Late
– Just In Time WithAdrian™