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1、Lean Production System,Kaizen Breakthrough Methodology,6 s Process Capability,Focus on lead-time reduction to:Increase Customer Loyalty and Market ShareSustain the Competitive AdvantagesAchieve Growth in Sales&EarningsImprove Stakeholder Value,LeanProductionSystem,LeanSigmaSM Transformation,Lean Pro
2、duction System,JustinTime,Jidoka,Efficient Use of:PeopleEquipmentMaterialsSpace,Production Smoothing,Improve Process CapabilityMinimize VariationManage Abnormality,Just-In-Time Is.,A manufacturing system which produces:What the customer wantsIn the quantity the customer wantsWhen the customer wants
3、it,While using the minimum:Raw materialsEquipmentLaborSpace,JIT Principles,Pace to“takt”timeCreate flow productionIncorporate“pull”system,Takt Time,“A Sea of WIP”,“Now You See It!”,Pull System,JIT Elements,Small,inexpensive machines in process orderOne-piece flow production,counterclockwiseErgonomic
4、ally-correct operationsStanding operations,moving while workingPull system discipline“Standard operations”defined and implemented,JIT Benefits,Eliminates waste in production processesReduces lead times,Quality Cost Delivery!,Creates a system which is intolerant of production abnormalities,Lean Produ
5、ction System,JustinTime,Jidoka,Efficient Use of:PeopleEquipmentMaterialsSpace,Production Smoothing,Improve Process CapabilityMinimize VariationManage Abnormality,Jidoka is,An immediate response to an abnormal condition within the processGoal:Prevent a defective product from being passed to the next
6、operation.Equipment autonomation capable machine processes that enable separation of machine and operatorGoal:Multi-process handling,increased labor productivity.,Abnormality Response Process,React to problem,Jidoka Elements,Visual Control5SAndonAbnormality Response/ReactionRoles and responsibilitie
7、sLine stop guidelinesRoot Cause Analysis(DMAIC)Basic QC ToolsAdvanced Statistical Tools,Mistake-proofing(Poke-Yoke)Manual WorkAutomatic machine workNew Standard Operations and trainingSkill matrix and performanceAutonomation Separate person from machine,Have Machines Detect Abnormalities,Metal Punch
8、 Press Example,Jidoka Benefits,Increases production qualityIncreases productivityEnsures on-time delivery,Quality.Cost.Delivery!,Lean Production System,JustinTime,Jidoka,Efficient Use of:PeopleEquipmentMaterialsSpace,Production Smoothing,Improve Process CapabilityMinimize VariationManage Abnormality
9、,Production Smoothing Is.,Adapting production rates to variations in customer demand:Variation in volumeVariation in product mix,Variation in Volume,Time,Variation in Mix,Production Smoothing Benefits,Maintains a consistent,high product qualityReduces the requirements for capital investmentReduces staffing costsEnsures on-time delivery,Quality.Cost.Delivery!,“Results in Cost Reduction”,
