Road Map for Implementing Lean Manufacturing

1 → Identify a product family (with similar routings) to start with and an

area to begin in, usually at or near final assembly
2 → Determine daily demand rate for each item
3 → Identify processes for common items to be included in lean cell/line
4 → Calculate takt times for each process
5 → Define the standard work content
6 → Calculate amount of resources for each process
7 → Determine cell/flow line general layout
8 → Balance the Work Flows
9 → Calculate the number of kanban containers (the amount of WIP)
10 → Follow the Steps for Implementing a Lean Project (Implementation Level 3)
11 → Begin to use pull signals to draw material from the feeder operations and
outside suppliers, but continue to use inventory as a buffer until they can
respond to the pull signals
12 → Develop Lean capabilities, following the Steps for Implementing a Lean
Project, for the next upstream feeder operation
13 → Follow step 11 for this feeder operation
14 → Repeat steps 12 and 13, cascading up the supply chain, for the next upstream
operation, and for the key suppliers