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Lean Manufacturing: Continuous Improvement Program

Our company is growing rapidly each year but faces challenges with inventory levels, on-time production, and maintaining quality. To address these issues and continue growing, we will implement a continuous improvement program using Lean Manufacturing principles. Lean focuses on eliminating waste to produce more with less. Key aspects include forming cross-functional teams to analyze processes, identify waste, and develop solutions through open communication and an ongoing improvement culture. The ultimate goals are to produce more efficiently using current resources and lower inventory levels while meeting customer demands.

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zakari
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40 views

Lean Manufacturing: Continuous Improvement Program

Our company is growing rapidly each year but faces challenges with inventory levels, on-time production, and maintaining quality. To address these issues and continue growing, we will implement a continuous improvement program using Lean Manufacturing principles. Lean focuses on eliminating waste to produce more with less. Key aspects include forming cross-functional teams to analyze processes, identify waste, and develop solutions through open communication and an ongoing improvement culture. The ultimate goals are to produce more efficiently using current resources and lower inventory levels while meeting customer demands.

Uploaded by

zakari
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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CONTINUOUS IMPROVEMENT PROGRAM

Lean
Manufacturing
Our company continues to grow
at 15% to 20% each year.
OUR CUSTOMERS WILL SAY

“Hasta La vista baby !!”


Our inventory in the stock room
grows.

$$$$$$$$$$$$$$$$$
How do we grow ?

How do we make the right product


on time ?

How do we lower our stock room


inventory ?

How do we maintain a good


quality product ?
We could hire more people
and buy more machines.
This would cost us $$$$

We could raise the price of our


products.
Currently our customers are asking us
to REDUCE the price of our products!
BEFORE WE DO ANYTHING ELSE

We need to become more


efficient in our manufacturing.

AND

We need to find waste in our


process and cut it out.
> Produce more product using
our current resources.

> Lower our stock room inventory.

> Accurately forecast exactly how long it takes to


make our products and ship them on time.

> Get all of the needed parts to Assembly at


the right time.
What is

LEAN

A systematic approach to identifying and


eliminating waste through continuous
improvement in pursuit of perfection.

Striving to do more with less, and do it


consistently.
Work Smarter Not Harder
TEAMWORK
FORM A TEAM OF PEOPLE,
THE PEOPLE THAT ACTUALLY
DO THE WORK

OBSERVE IDEAS
ANALYZE THE CURRENT THE TEAM DEVELOPS IDEAS
SITUATION ON HOW TO ELIMINATE WASTE

COMMUNICATION CULTURE
MAKE SURE EVERYONE KNOWS CREATE A CONTINOUS
THE GOALS, THE CHANGES IMPROVEMENT CULTURE.
BEING MADE, THE SUCCESSES, ALWAYS CONSIDER NEW IDEAS
AND THE FAILURES
8 Forms of Waste
DEFECTS
WAITING Repair or EXCESS
Any non-work time Rework. MOTION
waiting for tools, Any wasted motion
supplies, parts, etc.. to pick up parts or
stack parts. Also
wasted walking.
PROCESSING
OVER-
Doing more work than
is necessary. Types PRODUCTION
Producing more
of than is needed
Waste before it is needed.
UNDERUTILIZED
PEOPLE
Waiting for more TRANSPORTATION
Work to do. Transporting parts, or
INVENTORY finished goods into or
Maintaining excess out of storage, or
inventory of parts in between processes.
process, or
finished goods.
We the operations. We

We the operations.
the operations.

VALUE STREAM MAP

FINDING WASTE
LEAN TOOL BOX
5S TOOLS
SORT, SET IN ORDER,
SHINE, SET RULES, SUSTAIN. STANDARDIZED WORK
PRACTICES

TEAMS VISUAL CONTROLS


PLANT
LAYOUT

BATCH
QUICK REDUCTION
CHANGEOVER

QUALITY AT POINT
THE SOURCE OF USER
STORAGE
PRODUCTION
CELL
SUPERMARKET FLOW TOTAL PRODUCTIVE
PULL SYSTEM MAINTENANCE
Kaizen Kaizen Event

The definition of “Kaizen” has been


Americanized to mean "Continual
Improvement." A closer definition of the
Japanese meaning of Kaizen is "to take
apart and put back together in a better
way."
ISOLATION
SECRECY

“Do you have


any ideas ?” “Here’s what
we are doing”

“What problems
Can we solve ?” “Here’s where COMMUNICATION
We are going”

“How can we make


this better ?”

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