LEAN Basic Introduction (Quality)

29 Sep 2020

Mario F. Ramos
Operational Excellence 1
Sept-2020
 WHAT is LEAN?
Identifying
WASTE

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

Overburden
Beyond one’s power
Excessiveness
Unreasonableness
 Identifying
WASTE

5S
6
 What is 5S?
A method of creating a _____
clean and _______
orderly workplace in order to
expose _______ visible
WASTE and makes abnormalities immediately ______.
SAFETY and ________
Eliminates or Reduces _______ QUALITY risk.

Origin of 5S
Henry FORD : Cleaning
C up
A
Arranging
Neatness
N
D
Discipline
O
Ongoing improvement
7
 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. Place for everything.
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.

8
8 WASTE – D-O-W-N-T-I-M-E
Identifying
WASTE

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

9
 D-O-W-N-T-I-M-E
DEFECT
Products, services and information that
are defective, unusual, inaccurate or
incomplete, do not meet customer
expectations.

Scrap produced by poorly maintained jigs/fixtures/machine

Parts assembled with the incorrect orientation
Missing parts due to lack of controls
Incorrect components used due to incorrect, or missing
instructions
Poorly made components from supplier
Parts damaged due to excessive handling
Uncleaned toilet due to lack of budget
Wrong reports due to incorrect data entry or formula
Missing report due to wrong information
Software bug
11
 D-O-W-N-T-I-M-E
OVER PRODUCTION
Produce or buy more than how much is
needed or make sooner than when is
needed.

Schedule a production ahead before the next process /

customer need in few minutes (WIP), hours (module) or
days (shipping)
Buy or purchase in advance or more than what is needed
Printing and filing of unnecessary documents of forms
Cooking of food that are partially ordered or eaten
Reports that are not needed
Videos or pictures that are not seen or use

12
 D-O-W-N-T-I-M-E
WAITING
Idle time on work or information. Spending
time doing nothing or not moving including a
material, person or product.

Breakdown – Operators / machines are not doing anything

No order – machines/lines are idle
Time to print
Wait for previous or next process to flow
Wait for materials
Wait for instruction
Late in meeting
Information
Request waiting in queue
PR / PO waiting for approval
13
 D-O-W-N-T-I-M-E
NOT UTILIZING RESOURCES
Talents, skills, knowledge, technology,
machines were not use in current
position, job, issue, problem.

Employees spend time on task that do not add value

Career development, training and planning were absent
People with advanced skills or expertise do routine work
Personnel assigned to the area that he/she does not have
experienced, no passion to learn, or not his/her career goal
Kaizen ideas are ignored
Available technology, machines but not use or rarely use
Needed technology but not brought

14
 D-O-W-N-T-I-M-E
TRANSPORTATION
Is the movement of materials or stuff from one
area to another. Moving things around to
where is needed.

Air, sea or truck

Production line to OBA room and back
High rack to kitting area, and back to high rack
Raw material to production line
Module to Warehouse
FG to High rack
Tools, jigs, fixtures movement from spare parts room to where is
needed
Chemicals from store room to machine

15
 D-O-W-N-T-I-M-E
INVENTORY
Materials, SFG, FG, documents, consumables,
spare parts or anything that is in stock.

Raw materials in warehouse

FG in Shipping
WIP in production
FG for OBA
Documents stored
Raw foods in kitchen
Spare parts, consumables, chemicals, jigs, tools
Jigs, fixtures, stencils, office supplies
Unused equipment

16
 D-O-W-N-T-I-M-E
MOTION
Unnecessary movement or actions of man
or machine.

Material presentation
Reaching
Walking
Lifting
Opening
Twisting
Bending
Searching
Stroke
Too many clicks in a software
Writing down information/s 17
 D-O-W-N-T-I-M-E
EXCESS PROCESSING
Added steps or effort taken to get things right.
Doing more than the customer had asked for.

Rework a defect
All things need to be re-inspected: Including products,
formula, report
Air gun blowing
Higher quality standard or specification than what is
required
Energy waste due to over used or not needed
Multiple level approval for a small request
Sending unqualified applicants to hiring manager
18
8 WASTE – D-O-W-N-T-I-M-E

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

19
Root Cause Analysis
Make the clear problem statement.
Problem Statement
Who
What
When
Where
Why
How
 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

24
5 Whys
What’s the Root Cause?
Analysis
 What’s the Root Cause?

https://www.youtube.com/watch?v=hUdhPmcJPRE
7 QC Tools
 7 QC Tools
2. Giải quyết các vấn đề với 7 công cụ QC
Biểu đồ Pareto
Pareto chart
Nguyên nhân & hiệu quả 1
Cause & effective Biểu đồ kiểm soát
Control chart
2 5
Biểu mẫu

4
Biểu đồ Histogram Biểu đồ phân tầng
Histogram Stratification
3 6
Biểu đồ tán xạ
Scattering
7 chart
 Lean is Simple: Example 1
BEFORE AFTER

31
 Lean is Simple: Example 2
AFTER
BEFORE

32
 Lean is Simple: Example 3
BEFORE AFTER

Label is the same Color coded label by

and handwritten PRODUCT name
33
 Lean is Simple: Example 4
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.
34
 Lean is Simple: Example 5
BEFORE AFTER

Designated marking to know: Designated marking to know:

Pattern A,B,C = ex. B Pattern A = Dot, B= dash,
Group =G C=stick
OP no. = 11 Group = not use
OP no. = designated
CG11 location in the material

35
Knowledge Check #1
Knowledge Check #1 -sample

37
Knowledge Check #2

38
Knowledge Check #3

2 39
Knowledge Check #4

40
Knowledge Check #5

41
 Do It Right the First Time
Aim for PERFECT
PERFECTion to achieve:
EXCELLENCE
If there is no Standard, there is no IMPROVEMENT.

42
Operational Excellence
Slogan
K eep
I t
S imple &
S tandard

43
Thank YOU.

Mario F. Ramos
Operational Excellence 44
Sept-2020