Lean Overview
Days: 2.5
Prerequisites: None
Course Outline:
What is Lean?
- Lean is a concept that involves the removal of waste from every step in the production chain – waste of energy, motion, time, and resources.
· *7 types of waste
· Lean keeps cost down so that companies can remain competitive.
Pre-requisites: (Detailed)
· Communication
· Teamwork
· Employee Empowerment
· Management Support
· Training
How does Lean Manufacturing work? (Detailed)
Step 1 Define waste
Step 2 Identify the source
Step 3 Plan for the elimination of waste
Step 4 Establish permanent controls to prevent reoccurrence
5S
-Textbook definition
5S – define every step of this process
-Sort (hit lightly on the 7 types of waste – prepare for lean overview)
*Red Tag Hold Area
-Set in order
*organization, labeling, structure, etc
-Standardized
*work instructions, job descriptions, methods, procedures, etc
-Shine
*tools, techniques, visual displace examples
-Sustain
*Management Responsibility, Tools & Methods to sustain
Additional Information: What will happen if you do not sustain? What will happen if you stop after shine? What will happen if you do not build a system that is understood and standardized? What will happen without management support? What will happen without resources and time to implement?
Visual Controls
-Textbook definition
Types of Visual Controls
-Pictures
-Colors
-Lights
-Sounds / Noise
-Shapes / Sizes
-Location
When, where, why and how to use visual controls:
When: whenever possible for clarification / understanding (Barriers: Language, Color Blindness, Special Needs, etc.)
-Examples: Color Blindness, Statistics on illiteracy, etc.
Where: universal system, it can be used anywhere (examples: home, play, office, etc.)
Why: Safety, Quality, Cost, Delivery
Makes the operators job easier
Visual Work Place – define
Easier to formulate controls for required customer documentation
How: by using a standardized method for implementation that is used in the office and on the production floor (repetition and consistency)
Who: is responsible for visual controls?
-Everyone is responsible for visual controls