LEAN PRINCIPLES, METHODOLOGY & TOOLS

>> Start “thinking Lean”

>> Acquire basic knowledge of Lean tools for removing waste and enhancing customer value

>> Begin to apply Lean in your area of work through Lean projects

>> Get Lean Certification

Learning Objectives

Learning Objectives

Learning objectives


  1. Start “thinking Lean”
  2. Acquire basic knowledge of Lean tools for removing waste and enhancing customer value 
  3. Begin to apply Lean in your area of work through Lean projects 
  4. Get Lean Certification

Module I - What is Lean?

What is Lean?

What is Waste?

What is Value?

Lean Helps Us Understand…

Pricing Model

Module II – History of lean

How Lean Started?

How Lean Started?

How Lean Started? ….continued

The focus of lean is to –

  • When customer demands reduction in price, reduce the price only
  • When customer demands reduction in price, first reduce the cost of manufacturing in order to maintain the profit with reduced price
  • When customer demands reduction in price, do nothing
  • When customer demands reduction in price, offer discounts to the customer

Module III - Lean Principles

The 5 Lean Principles

1. Specify Value

1. Specify Value

How do we Define Value Added (VA)?

Non-Value Added (NVA) Activity….

Non-Value Added (NVA) Activity….

Value Add / Non Value Added Activities

Identify Value Add/Non Value Add

  • Chasing a late stationary order
    Non Value Add
  • Online order of some flight ticket
    Value Add
  • Customer requesting further help to fill in an insurance claim form
    Non Value Add
  • Call to IT helpdesk = "My computer is very slow"
    Non Value Add
  • A garage receiving a car for a routine service
    Value Add

2. Identify the Value Stream

3. Flow

4. Pull

5. Perfection

Module IV - Lean Concepts and Tools

Lean Concepts & Tools

Value Stream Map

An Example

Identifying Muda

8 Wastes: Defects

8 Wastes: Overproduction

8 Wastes: Waiting

8 Wastes: Non-utilized Talent

8 Wastes: Transportation

8 Wastes: Inventory

8 Wastes: Motion

8 Wastes: Extra Processing

Mudas – Summary

Classify type of Waste

  • Multiple Approval
    Extra processing
  • Batch waiting for further processing
    Waiting
  • Employees walking several times between different floors
    Motion
  • Too many books printed for the training
    Over Production
  • Estimation rejected by the customer
    Defect

Kaizen

KANBAN (Pull system)

Standardization

ANDON – Visual Controls

TAKT Time

Available Time

TAKT Time

Line Balancing

Continuous Flow Using Cells

Continuous Flow – Implementation

Reducing Waiting Time: An Illustration (Banking Unit)

Reducing Waiting Time: An Illustration (Banking Unit)

5S – Making Improvements Visible

5 S

Place for everything and everything in its place is an example of

  • Line Balancing
  • Mistake Proofing
  • VSM
  • 5S

There is only one way to connect a projector socket with a laptop/desktop, if done incorrectly it is detected 100%. This is an example of:

  • Line Balancing
  • Mistake Proofing
  • VSM
  • 5S

Module V – Implementing Lean

Lean Project Phases

Discover

Lean Project Charter

Assess

Create As Is Value Stream Map (VSM)

Waste Identification

Waste Quantification

Assess -As Is process

Deploy

Design To Be Process

Treatment of Identified Wastes

Pilot / Implementation Plan

Validation of Improvement

Sustain

Sustenance Plan

Design Failure Mode & Effect Analysis (FMEA)

Monitor Sustenance

Benefits

Feedback/Further Support

DI Service Excellence Team

VARSHA DEB

CUG: 0121 635 6270 

Mobile:+91 958814727 

[email protected].

KULJYOTI SAHNI

CUG: 0121 635 6697 

Mobile: +91 9811033772 

[email protected]