LEAN Basic Introduction (Shipping)

09 Sep 2020

Mario F. Ramos
OE – Sept-2020
1
 WHAT is LEAN?
Identifying
WASTE

SIMPLE
Eliminate
those
WASTE
2
 3 M’s of WASTE
Wastefull
Useless MUDA
Non-Value Add
MURA Un-evenness
Non-uniformity
Irregularity

Overburden
Beyond one’s power
Excessiveness
Unreasonableness
8 WASTE – D-O-W-N-T-I-M-E

8
D-O-W-N-T-I-M-E

5
 5S
Actions: Segregate. Remove unnecessary items. Keep area clear except those needed.
Sorting Benefits: Reduce: time of searching, distraction. Increase useful space. Safety.

Actions: Fixed location. Put all necessary items in optimal place. Clear labels.
Set In Order Benefits: Can easily select what is needed. Makes workflow smooth and easy.

Actions: Workplace and equipment need to be Clean and Inspect while cleaning.
Shine Benefits: Prevents errors and defects.

Actions: Standardize the process. Develop work structure. Visual controls.

Standardize Benefits: If there’s no standard, there is no improvement.

Actions: Regular audit.

Sustain Benefits: Ensure that 4S is followed. Discipline.

6
 GEMBA
The actual place where value is created
Get out of your chair / office
Go to the actual
Perceive and register place
it as being significant OBSERVE
to learn something
Ask the right
question/s
Paying attention,
do consciously

7
 Visual Management
Visual Management

is a way to visually communicate expectations, performance, standards or warnings in

a way that requires little or no prior training to interpret.

is the use of techniques that will enable a person to easily or immediately recognize
normal and abnormal states in a process.

It helps us to examine the workplace and identify irregularities for easy elimination of
waste and improving safety.
Lean is Simple: Example 1
BEFORE AFTER

9
 Lean is Simple: Example 2
AFTER
BEFORE

10
 Lean is Simple: Example 3
BEFORE AFTER

11
 Lean is Simple: Example 4
BEFORE AFTER

Label is the same Color coded label by

and handwritten PRODUCT name
12
 Lean is Simple: Example 5
BEFORE AFTER

Jig have the same label for 5V, 7.5V and 12V.
No label for adaptors. Color coded label wrt voltage of Power supply.
Both items were stored in 2 different Yellow = 5V
locations. Blue = 7.5V
Green = 12V
Label both jig and adaptor.
13
 Knowledge Check #1

What’s the WASTE of DEFECT that you can find in this shipping Document?

What are the improvements that you can do?

14
 Knowledge Check #2

What’s the WASTE: DEFECT or POTENTIAL DEFECT and

EXCESS PROCESSING that you can find in this shipping Document?

What are the improvements that you can do?

15
 Do It Right the First Time
Aim for PERFECT
PERFECTion to achieve:
EXCELLENCE
If there is no Standard, there is no IMPROVEMENT.

16
Operational Excellence
Slogan
K eep
I t
S imple &
S tandard

17
Thank YOU.

18