SPS Section 1 V3.0 English

Training
Lean & Flow Manufacturing
SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

1
Lean & Flow Manufacturing Training
Contents
Section 1 - Introduction : Lean & 6 sigma
Section 2 - Customer Need
Section 3 - Product / Process
Section 4 - Process / Equipments
Section 5 - Material Providing & Handling
Section 6 - Short Interval Management (SIM)
Section 7 - Guiding principles of SPS
2
Objectives of Lean & Flow Manufacturing training
 Target:
 All people who Run, Modify or Design, manufacturing
processes.
 Objectives:
 Be able to apply Lean Manufacturing concept to production systems:
LINE DESIGN
 Be able to apply the rules of Material Providing & Handling system to
the workstations: MPH
 Understand the impact of these organizations on the management of
the manufacturing and support function teams: SIM

3
TRAINING
Section 1
- Introduction
- Six Sigma & Lean Manufacturing

4
Industrial policy extract
Industrial Policy
Industrial Orientations
The orientations are defined according to 6 major, interdependent

guidelines:
Make or Buy
choices
Plant
vocation
The Schneider
Production
System Plant
location
Global
supply chain Product /
management process design
G&I – I ndustrial Deployment - Industrial Policy – V2005 - lbt 4

5
Industrial policy extract
Industrial Policy
The Schneider Production System
 Incorporate Lean Manufacturing concepts and Six Sigma

concepts/methods as core tools for improvement in factories
 Define and apply the same common prescriptions for production

lines, performance indicators and flow management systems
 Increase industrial competencies to reach manufacturing

excellence
G&I – Industrial Deployment - Industrial Policy – V2005 - lbt 10

6
SPS definition
 SPS (Schneider Production System) is a "Set of common

prescriptions for production lines, performance indicators and
flow management systems" (Schneider Industrial Policy)
 SPS:
 generalize Lean Manufacturing and Six Sigma concepts.
 formalize manufacturing fundamentals and principles.
 Define the framework of processes, methodologies and tools

7
SPS
g ma
Si
Six n
Lea uring
fa c t
u
SPS Man
Processes
Methodologies
Tools

8
SPS / IPDA (Industrial Process Design Approach)
g ma
Si
Six n
Lea uring
u fa ct
SPS Assessment
Management
Man
Layout
Specifications
IPDA
Flows
Product/
process Manufacturing
process
A
D
IP
9
Main handled subjects of L&F training
Other mentionned subjects
g ma
Si
SIM Six n
Short Interval
Lea uring
Management
u fa ct
SPS Assessment
Management
Man
Layout
Specifications
IPDA MPH
Material Providing
P.P.L.T. Flows & Handling MTM
Placing process 5S
Product/ Kanban
in a lead time process Manufacturing SMED
contract process FMEA
Lean
Process Poka yoke
VSM
...

1
0
Lean & Flow Manufacturing training : Guiding thread
SPS
Schneider Production System
The 40 Guiding Principles
Satisfaction
Implementation of Lean manufacturing concepts
Impact on the System
Customer Product Process Operations Workstations Components Management

1
1
Objectives:
 Understand and learn definition of Capacity (Cmax) and Takt Time Calculation
 Understand and learn Process Synchronisations.

 Understand and learn Process Mapping.
 Understand and learn IE (Industrial Efficiency)
 Introduce MTM (Method Time Measurements)
 Understand and learn Balancing Techniques
 Understand and learn Initial Line Design Calculations
 Understand and learn MPH ( Material Providing and Handling )
 Implementation of a pull system ( Pull Signal )
 Define Final Line Architecture
 Understand concept of management SIM
1
2
TRAINING
Section 1
- Introduction
- Six Sigma & Lean Manufacturing
Two concepts to try to achieve "processes excellence"
for a common objective : « Industrial Excellence »
a
gm
Si
6
1
3
Complementarity of the
Lean Manufacturing and 6 Sigma projects
Generally, when faced with problems, we are led to

compensate (additional controls,
stocks...) => which generates wastes
Variability
Stocks
Product
lead Failures &
time Break
Non quality
Downs

1
4
The solution : tackle the problems by
using 6 Sigma and Lean Manufacturing
Methodology
The principles of 6 Sigma
Lean Manufacturing
Variability
Stocks
Product
lead Failures &
time Non quality Break
downs

1
5
We get rid of problems (non quality, breakdowns,

variability...) by using the 6 Sigma methodology
Variability
Reduction
of
wastes
Non quality Failures

1
6
After reducing the risks,

we can reduce work in process, stocks and product lead time
with Lean Manufacturing
Trade Winds
Paradise Lagoon
Just
Necessary
Non quality Failures

1
7
Two progress programs for a common objective
Six Sigma Lean Manufacturing

« Open to trained people » Implemented by experts
Methodology & advanced tools Share manufacturing people
Approach  Reduce variability.  Concentrate on non-added value to the

customer
 Reduce wastes.
Focus  A performance to reach on a process.  The whole product flow and its DVC costs
( including support functions)
 Measure, quantify, identify and
Methodology eliminate main causes of variability,  All the methodologies & tools for solving
improve statistic process control. problems.
 Re-engineer layout and organizations
 The global performance is getting (Hoshin, etc…)
better each time a variation cause is
1st Effect suppressed.  Reduce costs and cycle times,
WIP,stocks.
Objective Common to contribute to the industrial performance

Quality Lead time Cost

1
8
Two different programs but complementary and
indispensable for excellence
 A 6 Sigma program will be more effective with simple production flows
 A Lean Manufacturing program will be more effective with variability

under control
 these two programs need specific competencies and different project

organizations

1
9

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Training

Lean & Flow Manufacturing

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

The orientations are defined according to 6 major, interdependent

G&I – I ndustrial Deployment - Industrial Policy – V2005 - lbt 4

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

The Schneider Production System

 Incorporate Lean Manufacturing concepts and Six Sigma

 Define and apply the same common prescriptions for production

 Increase industrial competencies to reach manufacturing

G&I – Industrial Deployment - Industrial Policy – V2005 - lbt 10

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

 SPS (Schneider Production System) is a "Set of common

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

Implementation of Lean manufacturing concepts

Impact on the System

Customer Product Process Operations Workstations Components Management

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

 Understand and learn Process Synchronisations.

Generally, when faced with problems, we are led to

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

We get rid of problems (non quality, breakdowns,

Non quality Failures

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

After reducing the risks,

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

Six Sigma Lean Manufacturing

Approach  Reduce variability.  Concentrate on non-added value to the

Objective Common to contribute to the industrial performance

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

 A 6 Sigma program will be more effective with simple production flows

 A Lean Manufacturing program will be more effective with variability

 these two programs need specific competencies and different project

SPS 0073 EN ind AC Section 1: Formation lean & flow manufacturing

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