13. LEAN OPERATIONS

toyota production system

Lean concepts originated from

taiichi ohno

who developed lean concepts

value

defined as anything the customer would be willing to pay for, whether that’s a hard good, a service or time.

waste

defined as anything that does not add value to either the customer or the production process.

lean operations

A systematic approach to enhancing processes by eliminating waste (muda), increasing efficiency, and delivering maximum value to the customer. It heavily focuses on continuous improvement, streamlined workflows, and respect for people.

1. specify value

2. identify the value stream

3. flow

4. pull

5. pursue perfection

lean thinking principles

sort

one of the 5s system that Clearly distinguish between what must be kept and what is unneeded and should be discarded.

seiri

japanese word for sort

set in order

one of the 5s system that Organize necessary items so anyone can easily find and use them.

seiton

japanese word for set in order

shine

one of the 5s system that Sweep floors, keep things orderly, and prevent the buildup of dirt and dust.

seiso

japanese word for shine

standardize

one of the 5s system that Maintain the first three pillars (Organization, Orderliness, and Cleanliness) consistently.

seiketsu

japanese word for standardize

sustain

one of the 5s system that Make a habit of always following the established, standardized procedures.

shitsuke

japanese word for sustain

1. red tagging

2. shadow boards

3. floor marking tape

4. signage

tools in 5s system

transportation

1 of the 7 waste that is described as Unnecessary movement of materials or products.

inventory

1 of the 7 waste that is described as Excess raw materials, work-in-progress, or finished goods

motion

1 of the 7 waste that is described as Unnecessary movement of people

waiting

1 of the 7 waste that is described as Idle time or waiting for materials and information

overproduction

1 of the 7 waste that is described as Producing earlier or in greater quantities than needed

over-processing

1 of the 7 waste that is described as Doing more work than is necessary

defects

1 of the 7 waste that is described as Errors that result in waste or require rework

just-in-case

A system built for inventory that operates on production approximation and anticipated usage. It results in large lots, high inventories, more waste, and poor communication.

just-in-time

A system made to order where demand dictates production. It operates on actual consumption and production precision, resulting in small lots, low inventories, less waste, and better communication. JIT eliminates large stocks by relying strictly on prompt deliveries of components only when requested.