[PDF] [PDF] Lean Operations

[PDF] Lean manufacturing - INRS

Le lean manufacturing ou simplement lean (littéralement « maigre », « épuré ») trouve son origine dans le Toyota Production System (TPS) élaboré par Taïchi 

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Lean Operations Management is both an art and a science, tying together quantitative analytical skills with cognitive problem solving and decision making 

[PDF] Lean Operations

Explain what is meant by the term lean operations system 2 List each of the goals List and briefly describe the building blocks of lean 4 List the benefits of a 

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Lean Manufacturing focuses on operations, processes, technology, quality, capacity, physical arrangement, supply chains, inventory and resource planning  

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Lean Operations

McGraw-Hill/IrwinCopyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved. yYou should be able to:

1.Explain what is meant by the term lean operations system

2.List each of the goals of a lean system and explain its

importance

3.List and briefly describe the building blocks of lean

4.List the benefits of a lean system

5.Outline the considerations important in converting a

traditional mode of operations to a lean system

6.Point out some of the obstacles that might be encountered

when converting to a lean system

7.Describe value stream mapping

Instructor Slides14-2

yLean operation yA flexible system of operation that uses considerably less resources than a traditional system yTend to achieve yGreater productivity yLower costs yShorter cycle times yHigher quality

Instructor Slides14-3

yThe ultimate goal: yAchieve a system that matches supply to customer demand; supply is synchronized to meet customer demand in a smooth uninterrupted flow yA balancedsystem yOne that achieves a smooth, rapid flow of materials and/or work through the system

Instructor Slides14-4

Instructor Slides14-5

depends upon how well its supporting goals are achieved:

1.Eliminate disruptions

2.Make the system flexible

3.Eliminate waste, especially excess inventory

Instructor Slides14-6

yFive personnel/organizational elements that are important for lean systems: yWorkers as assets yCross-trained workers yContinuous improvement yCost accounting yLeadership/project management

Instructor Slides14-7

ySeven elements of manufacturing planning and control (MPC) are particularly important for lean system:

1.Level loading

2.Pull systems

3.Visual systems

4.Limited work-in-process (WIP)

5.Close vendor relationships

6.Reduced transaction processing

7.Preventive maintenance and housekeeping

Instructor Slides14-8

yIdeal number of kanbancards part theof usagedaily percentof 10than more no be (shouldcontainer standard a ofCapacity system theefficient more the0, closer to (the system in the cyinefficien possible relects that managementby set iablePolicy var parts ofcontainer afor timeproduction average plus parts ofent replenishmfor time waitingAverage center work using of rate usage planned container)per card (1 containers ofnumber Total where )1( C X T D N C XDTN

Instructor Slides14-9

yPreventive maintenance yMaintaining equipment in good operating condition and replacing parts that have a tendency to fail before they actually do fail yHousekeeping yMaintaining a workplace that is clean and free of unnecessary materials

Instructor Slides14-10

1.Make sure top management is committed and that they know what

will be required

2.Decide which parts will need the most effort to convert

3.Obtain support and cooperation of workers

4.Begin by trying to reduce setup times while maintaining the

current system

5.Gradually convert operations, begin at the end and work

backwards

6.Convert suppliers to JIT

7.Prepare for obstacles

Instructor Slides14-11

1.Management may not be fully committed or willing to

devote the necessary resources to conversion

2.Workers/management may not be cooperative

3.It can be difficult to change the organizational culture

to one consistent with the lean philosophy

4.Suppliers may

resist

Instructor Slides14-12

yIn service the focus is often on the time needed to perform the service because speed is often the order winner yLean benefits can be achieved in the following ways: yEliminate disruptions yMake system flexible yReduce setup and lead times yEliminate waste yMinimize WIP ySimplify the process

Instructor Slides14-13

yJIT II: plant, making sure there is an appropriate supply on hand wIt is often referred to as vendor managed inventory (VMI)

Instructor Slides14-14

yBe careful to study the requirements and benefits of lean systems before making a decision to convert operations yEvaluate strengths and weaknesses of current operations yThe decision to convert can be sequential yWeigh the pros and cons of a lean approach to inventories ySupplier management is critical to a lean operation

Instructor Slides14-15

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