LEAN IMPLEMENTATION

CREATE PRODUCT VALUE – CPV

Connectivity & alignment LEAN PRE-PRODUCTION on FOOTWEAR INDUSTRY
Project Manager – Costing – R&D - Quality – LEAN – OE – IE – ME – Technology - Supplier & Production
AGENDA & TOPIC DISCUSSION
LEAN IMPLEMENATION at FOOTWEAR INDUSTRY : CREATE PRODUCT VALUE (CPV)

1 2 3
PROFILE & BACKGROUND 5 BASIC LEAN PRINCIPLE LEAN VALUE
Short introduction & Working Understand fundamental of Definition, What is LEAN Value &
Experience sharing LEAN principle What value are customer want

4 5 6 7
CREATE PRODUCT VALUE 5 KEY POINTS of CPV IMPLEMENTATION CPV KEY TAKE AWAY
Definition of CPV, How to increase values + Need all team support ,
Determined 11 principle with reducing the cost engagement collaboration
5 enabler
PROFILE & BACKGROUND
Short introduction & Working Experience sharing
5 BASIC LEAN PRINCIPLES
Understand fundamental of LEAN principle
LEAN VALUE
Define Value, What is LEAN Value & What value are customer want

Define VALUE
 The only perception of VALUE that counts is that perceived by the
CUSTOMER

Question – what do we do that the CUSTOMER is willing to pay for ?

the rest is WASTE - $$$

5
LEAN VALUE
What value are customer want & What are the Value

What does Customer want?

Achieve Quality, Service, Cost, Time (QCD) effectively and efficiently

Quality Service
= Value to the Customer
Cost Time
LEAN VALUE
What value are customer want & What are the Value

Increasing the overall value of

the product by
adding few value-added
element !!
CREATE PRODUCT VALUE - CPV
Definition of CPV, Determined with product principle & enabler

Is a way of evaluating the product to create efficiency, cost reduction, reduce time by
adopting effective method, at the same time do collaboration effort to maintaining or
increasing the VALUE of the PRODUCT

Determined 12 principle CPV :

MODULARITY

1. Reduce the total number of component part

2. Reduce the total number of materials & colors

JIGS - POKAYOKE
SMART TOOLS &
MAKE it SIMPLE
3. Reduce the total number of supplier

CPV
4. Maximized existing design, parts, or component
5. Maximized using modular components
6. Minimized complexity design
7. Minimized matching part
8. Minimized using different treatment or process type
9. Design for easy mass production
10. Do waste elimination
11. Understand the manufacturing process end to end
12. Do Regularly and storage the data for reference AUTOMATION
5 BASIC LEAN PRINCIPLES
How to increase values + reducing the cost _ Smart tools (Pokayoke)

Now what do we need to improve the

increase value and reduce cost?
HIGH OPERATOR
SKILL REQUIRED
With more complicity of the
product will need smart toolss
PROCESS VARIABILITY to support operator skill in
The more process in creation of work
the product will affect the
quality produced, so need a
smart tools for production
INCONSISTENT QUALITY efficiency – Smart Tools Design
The result of a poor process will
cause defect, so need smart tools or
jigs (pokayoke) for good
quality result - Smart Tools Design
PROCESS BOTTLENECKS
The process is non value added because
it will impactr the next process and need
to be analysis for the maximum output
of shoes – OPC Chart
HIGH CYCLE TIME
Conduct more analysis because it need
low cycle time values so the time base
and production targets could be
increased – IE Data
IMPLEMENTATION CPV
all team support engagement & collaboration effort

Working as a TEAM and Implementation System Effectiveness

Are the most important point for CPV : not Individual
 Step 1 basic Lean are Key to start
the CPV concept
Efficiency it’s all
 Step 2, 3, 4 are together as ONE
 Step 5 work for perfection are the
point for making lean thinking & “stop being efficient & start
process improvement as company being productive”
corporate culture
 Lean require constant effort and
vigilance to perfect

And to do implementation all of the step

have to Conduct and to gain the Value
KEY TAKE AWAY

UNDERSTAND THE CUSTOMER NEEDS

High Quality & Service with Low cost possible
+ faster SPEED process

CREATE PRODUCT VALUE Activity

Start to make value from beginning process
operation

IMPLEMENTATION
Do implementation and collect all data report
as reference for next order

PRACTICING LEAN & CI

There are always room for improvement and The
“Lean Process” is a continuous journey,
towards a destination we’ll never quite reach