dozuki workshop series: cal poly university's lean systems 101
TRANSCRIPT
Cal Poly University’s Lean Systems 101
Workshop Roadmap
Cal Poly University’s Lean Systems 101
• Defining “The Goal”
• “The House of Lean Tools”
• Types of waste
• Cal Poly’s Basic Elements
• Quality at the Source
• Benefits of Lean Production
• 5S and Visual Management
• Additional Resources
• Audience Q&A
Cal Poly University’s Lean Systems 101
THE GOAL: VALUE
Respect for People
Continuous Improvement
FOUNDATION: MANAGEMENT SUPPORT
Product Development
Flow
Cal Poly University’s Lean Systems 101
But how can you experience continuous improvement?
Eliminating waste.
Cal Poly University’s Lean Systems 101
CUSTOMER SATISFACTION BUSINESS SUCCESS
RESPECT FOR PEOPLE Team Building Empowerment Cross Training
Hoshin Supplier Relationships
JIT
Pull Flow
TAKT Time Heijunka
Cell Design SMED
JIDOKA
Poka-yoke And on Autonomation 5 Ways Line Stops Built in Quality
STABILITY & STANDARDIZATION
Cal Poly University’s Lean Systems 101
1. Finished Goods
2. Waiting
3. Transporting
4. Over Processing
Types of Waste
5. Factory Inventory
6. Movement
7. Defects
8. Talent
Cal Poly University’s Lean Systems 101
Types of Waste:
1. Finished Goods, 2. Waiting, 3. Transporting
Cal Poly University’s Lean Systems 101
Types of Waste:
4. Over Processing, 5. Factory Inventory
Cal Poly University’s Lean Systems 101
Types of Waste:
6. Motion, 7. Defects, and 8. Talent
Cal Poly University’s Lean Systems 101
Basic Elements
1. Flexible resources*
2. Celluar layouts*
3. Pull production system
4. Kanban production
5. Small lot production
6.Quick setups
7. Uniform production levels
8. Quality at the source*
9. Total productive maintenance
10. Supplier networks
Cal Poly University’s Lean Systems 101
Flexible Resources and Cellular Layouts
• Multifunctional resources
• Manufacturing cells
Cal Poly University’s Lean Systems 101
Multifunctional resources:
cross trained workers, general purpose
machines and equipment, and
common raw materials
Resources
Webinars
In-houseE-courses
Cal Poly University’s Lean Systems 101
Manufacturing cells: product layout and TAKT Time
BEFORE AFTER
A
B
C
A
B
C
Cal Poly University’s Lean Systems 101
Quality at the Source | Visual Control
Quality at the Source | Poka-Yokes
Cal Poly University’s Lean Systems 101
Cal Poly University’s Lean Systems 101
Basic Elements In Review
1. Flexible resources
2. Celluar layouts
3. Pull production system
4. Kanban production
5. Small lot production
6.Quick setups
7. Uniform production levels
8. Quality at the source
9. Total productive maintenance
10. Supplier networks
Benefits of Lean Production
Cal Poly University’s Lean Systems 101
• Reduced inventory
• Improved quality
• Lower costs
• Reduced space requirements
• Shorter lead time
• Increased productivity
• Greater flexibility
• Better relationships with suppliers
• Simplified scheduling and control activities
• Increased capacity
• Better use of human resources
• More product variety
5S and Visual Management
Cal Poly University’s Lean Systems 101
Cal Poly University’s Lean Systems 101
5S Scan: Seiri (sort)
Goal: Keep only what you need
Eliminate or correct: Unneeded equipment, tools, furniture; unneeded items on walls, bulletins; items blocking aisles or stacked in corners; unneeded inventory, supplies, parts; safety hazards
Cal Poly University’s Lean Systems 101
5S Scan: Seiton (set in order)
Goal: A place for everything and everything in its place
Eliminate or correct: Items not in their correct places; correct places not obvious; aisles, workstations, and equipment locations not indicated items not put away immediately after use
Cal Poly University’s Lean Systems 101
5S Scan: Seisou (shine)
Goal: Cleaning and looking for ways to keep clean and organized.
Eliminate or correct: Floors, walls, stairs, equipment, and surfaces; cleaning materials not easily accessible, labels, signs broken or unclean; other cleaning problems
Cal Poly University’s Lean Systems 101
5S Scan: Seiketsu (standardize)
Goal: Maintaining and monitoring the first three categories
Eliminate or correct: Necessary information not visible; standards not known; checklists missing; quantities and limits not easily recognizable; items can’t be located within 30 seconds
Cal Poly University’s Lean Systems 101
5S Scan: Shisuke (sustain)
Goal: Sticking to the rules
Eliminate or correct: Number of workers without 5S training; number of daily 5S inspections not performed; number of personal items not stored; number of times job aids not available or up-to-date
Cal Poly University’s Lean Systems 101
Additional Resources
• Gemba Academy
• Institute of Industrial Engineers
• Central Coast Lean
• “The Toyota Way” by Jeffrey Liker
Cal Poly University’s Lean Systems 101
Audience Q&A
LinkedIn: Dozuki
Twitter: @Dozuki
Forum: dozuki.com/Answers/Ask/Lean_Systems
Cal Poly University’s Lean Systems 101
Continue the Conversation
Cal Poly University’s Lean Systems 101
@CaitEmmaSmith
Director of Outreach Dozuki
Cait Emma Smith
Faculty Member California Polytechnic State University
Karen Bangs
Thanks for joining us today!