Wednesday, June 3, 2009

Lean Fundamental


Lean is a methodology to "lean" your process to remove anything non-value-added actions.

8 Deadly Waste by Lean (TO WISDOM)
(Unnecessary) Transportation - Moving material more than necessary.  This is often caused by poor plant design/layout or  placement.

Over Production Producing components that are not intended for immediate use or sale
Waiting Idle time between operations or during an operation due to missing material, an unbalanced line, scheduling  mistakes, etc.

(Excess) Inventory Excess stock in the form of raw materials, Work in Process, and finished goods
(Unused) Skills Not using or underutilizing employee skills limits the corporation’s ability to compete and excel
Defects (and Spoilage) Producing defective goods or mishandling materials.  This includes the waste inherent in having to  rework parts not made correctly the first time through

Over Processing Doing more to the product than necessary. Reducing such waste often involves eliminating unnecessary  work elements

(Unnecessary) Motion Any motion that is not necessary to the successful completion of an operation.  Obvious forms of  motion include back-and-forth movement in a workstation and searching for parts or tools

3M model:
This model is used to measure whether there is instability in the whole process. Cute and hard to remember the names of each M....

Overburden & Stress (Muri)
Unevenness & Variability (Mura)
Waste (Muda)
Ideal (Stability)

5S Methodology
This one is famous:
1S Sort
2S Set in order
3S Shine
4S Standardize
5S Sustain


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