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Lean Principles: Being Fast, Flexible, Economic Author: DR Rhys Rowland-Jones
Lean Principles: Being Fast, Flexible, Economic Author: DR Rhys Rowland-Jones
Lean Principles
Being Fast, Flexible, Economic Author: Dr Rhys Rowland-Jones
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Lean Principles
Session Plan:
What is lean? How does lean work? Who is lean applicable to? 5 principles of lean The Toyota Production System Taiichi Ohnos 7 Wastes 7 service wastes 5 Ss
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Lean Principles
What is lean?
Lean manufacturing was developed by the Japanese automotive industry, with a lead from Toyota and utilising the Toyota Production System (TPS), following the challenge to re-build the Japanese economy after World War II. The concept of lean thinking was introduced to the Western world in 1991 by the book The Machine That Changed the World written by Womack, Jones, and Roos. Lean is a philosophy that seeks to eliminate waste in all aspects of a firms production activities: human relations, vendor relations, technology, and the management of materials and inventory.
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Lean Principles
Standards in Action
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Lean Principles
Standards in Action
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Lean Principles
5 principles of Lean
Value - specify what creates value from the customers perspective. The value stream identify all the steps along the process chain. Flow - make the value process flow. Pull - make only what is needed by the customer (short term response to the customers rate of demand). Perfection - strive for perfection by continually attempting to produce exactly what the customer wants.
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Lean Principles
Value
Any process that the customer would be prepared to pay for that adds value to the product.
The customer defines the value of product in a lean supply chain. Value-adding activities transform the product closer to what the customer actually wants. An activity that does not add value is considered to be waste.
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Lean Principles
Standards in Action
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Lean Principles
The Value Stream is those set of tasks and activities required to design and make a family of products or services that are undertaken with a group of linked functions or companies from the point of customer specification right back to the raw material source.
(Hines et al, 2000)
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Lean Principles
Flow
Using one piece flow by linking of all the activities and processes into the most efficient combinations to maximize valueadded content while minimizing waste. The waiting time of work in progress between processes is eliminated, hence adding value more quickly.
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Lean Principles
Pull
Pull = response to the customers rate of demand i.e. the actual customer demand that drives the supply chain. Based on a supply chain view from downstream to upstream activities where nothing is produced by the upstream supplier until the downstream customer signals a need.
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Lean Principles
Perfection
The journey of continuous improvement. Producing exactly what the customer wants, exactly when, economically. Perfection is an aspiration, anything and everything is able to be improved.
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Lean Principles
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Lean Principles
3. 4.
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Lean Principles
types of waste:
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Lean Principles
7 Service Wastes
Source John Bicheno, Lean Toolbox (2003)
Delay customers waiting for service. Duplication having to re-enter data, repeat details etc. Unnecessary movement - poor ergonomics in the service encounter. Unclear communication having to seek clarification, confusion over use of product/service. Incorrect inventory out of stock. Opportunity lost to retain or win customers. Errors in the transaction, lost/damaged goods.
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Lean Principles
The 5Ss
The 5Ss are simple but effective methods to organise the workplace. The methodology does however, go beyond this simple concept, and is concerned with making orderly and standardized operations the norm, rather than the exception. Posters bearing the 5S terms can be found on the walls of Japanese plants, and are a visual aid to organisational management.
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Lean Principles
Straighten
Once Seiri has been carried out Seiton is implemented to classify by use, and arrange items to minimise search time and effort. The items left should have a designated area, with specified maximum levels of inventory for that area.
Seison
Shine
Seison means cleaning the working environment. It can help in the spotting of potential problems as well as reducing the risk of fire/injury by cleaning away the potential causes of accidents.
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Lean Principles
Shitsuke
Sustain
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Lean Principles
Summary
Lean manufacturing was developed by the Japanese. Lean is a philosophy that seeks to eliminate waste in all aspects of a firms production activities. Lean is principally associated with manufacturing industries but can be also equally applicable to both service and administration processes. Works on 5 basic principles. Cornerstone of Lean is the Toyota Production System. Considers 7 Wastes (muda). Utilises 5 S methodology.
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