ebook img

Lean Production for the Small Company PDF

288 Pages·2012·3.468 MB·English
Save to my drive
Quick download
Download
Most books are stored in the elastic cloud where traffic is expensive. For this reason, we have a limit on daily download.

Preview Lean Production for the Small Company

Productivity Improvement / Cellular Manufacturing / Just-in-Time E Lean Production for l b “Our Minnesota operation was the pilot plant and led our creative process improvements. e Mike was a leader at this site and had a huge impact on the required change management r activities and challenging the status quo. His out-of-the-box thinking and ability to apply his t knowledge to the operation were critical to our success. Mike has a deep understanding of the Small Company material flow.” —David Wambold, Vice President Lean Manufacturing, Beckman Coulter, Inc. L e “You can read about value stream mapping, eliminating non-value-added work, or Lean a manufacturing most anywhere; however, these are always so oversimplified they make n Lean difficult to apply. Mike Elbert effectively teaches the Lean fundamentals at a level that allows anyone to understand, take action, then follow through. He has implemented Lean at Mike Elbert P the front-line level. His methods will make a positive impact on your bottom line; but more r importantly, it will send a ripple of activity throughout your organization making a positive o impact on your culture.” d —Dennis Edwards, Operations Rapid Continuous Improvement Manager, Allsteel u A hands-on guide to adapting Lean principles and the Toyota Production System to high- c mix/low-volume environments, Lean Production for the Small Company uses charts, t pictures, and easy-to-understand language to describe the methods needed to improve i o processes and eliminate waste. It walks readers through the correct order of implementation and describes problems and pitfalls along with time-tested solutions. n f Explaining how to incorporate existing systems into a Lean strategy, the book starts with the o fundamentals and builds on them to describe the full range of tools and processes needed to r implement Lean. It outlines how to design factories for Lean manufacturing and demonstrates how to remove variations within business and manufacturing processes to achieve a smooth t continuous flow of product that delivers your product on time to customers. h e The tools, methods, and ideals discussed are applicable in any industry and all parts of your business—from manufacturing and sales to human resources. The text unveils new methods S and tools that can help you reduce inventory, improve inventory turns, and facilitate raw m material flow through the factory. It details how to use customer order demands to schedule the production floor, rather than using estimated production schedules. It also considers the a accounting process and explains how to improve your cash-to-cash cycle time. l l C Drawing on the author’s decades of experience transforming high-mix plants to Lean, the text covers the tools and processes that have made Toyota so successful. All the information in o this book, when implemented, will result in a culture change that will transform your company m into a learning organization that continuously eliminates waste and improves its processes. p a n K13607 y ISBN: 978-1-4398-7779-1 90000 www.crcpress.com 9 781439 877791 www.productivitypress.com K13607 mech-rev3.indd 1 6/21/12 11:30 AM Lean Production for the Small Company Mike Elbert CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2013 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Version Date: 20120611 International Standard Book Number-13: 978-1-4398-7780-7 (eBook - PDF) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the valid- ity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or uti- lized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopy- ing, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www.copyright.com (http:// www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com This book is dedicated to my wife Suretta and daughters Michelle and Danielle, without whom this book would not have been possible. I cannot express enough my love and gratitude for all their help and understanding, and all their support throughout the years. Contents Preface............................................................................................... xi About.The.Author..............................................................................xv   1  Introduction..................................................................................1 Who Should Use This Book .......................................................................1 How to Use This Book ...............................................................................2 Brief History of Lean Manufacturing ..........................................................3 The Philosophy of Lean Manufacturing and Business Systems ................5 Why Do We Need Lean Manufacturing and Business Systems? ...............7   2  Fundamentals.of.Lean.Production.and.Business.Systems............9 Nine Critical Wastes in Business ................................................................9 Concerning Elimination of Waste .............................................................11 Fundamentals of Lean Manufacturing ......................................................11 The Five Whys ..........................................................................................13 Critical Importance of Management Commitment ..................................14 Establish Your Lean Team and Lean Leader ............................................15 The Lean Coach ................................................................................16 Lean Coach and Consultants ............................................................18 Lean Team .........................................................................................18 Lean Production and Your Employees .............................................19 Some Will Leave Us (Making the Really Tough Decision, Removing Human Roadblocks) ..................................................................................21 Lean Systems versus Six Sigma ................................................................22   3  Tools.for.Continuous.Improvement............................................25 Step 1: Hands- On ......................................................................................25 Example: Order out of Chaos: ..........................................................25 Housekeeping: 5S ......................................................................................26 v vi  ◾  Contents   4  Beginning.Your.Journey.............................................................33 Waste Walk ................................................................................................33 Plant Manager: Waiting (Idle Time) ..................................................34 Materials Manager: Excess Inventory ................................................34 Finished Goods: Overproduction .....................................................34 Production Manager: Overproduction ..............................................36 Quality Manager: Defects ..................................................................36 Purchasing Manager: Environmental ................................................36 Planning Manager: Transportation ....................................................36 Manufacturing Engineering Manager: Excessive Motion .................36 Lean Leader: Overprocessing ............................................................37 Current Lean Status ...................................................................................37   5  Value.Stream.Maps:.The.Amazing.Tool. (Critical.to.Your.Success)............................................................39 What a Value Stream Map Is and Why You Need It ...............................39 Why a Value Stream Map Is Critical to Your Success ......................40 How to Create a Value Stream Map .........................................................41 Current State Map ..............................................................................41 Creating the Map ...............................................................................41 Gather Your Data ..............................................................................42 How to Read a Value Stream Map ...........................................................54 Future State Map ...............................................................................54 Creating the Future State Map ..................................................................61 Next, Compare the Current State Map to the Future State Map .............72   6  Identify.Your.Projects.................................................................77 Continuous Improvement Projects ...........................................................77 Identifying Your Projects from Your Maps ...............................................78 Which Project to Do First? ........................................................................79 Machine Tools and Takt Time ..................................................................86 Smoothing the Flow of Production ..........................................................87 Balancing Product Mix in the Work Cell .................................................89 Implementation .........................................................................................90 Audits .........................................................................................................91 Who Should be Audited? ..........................................................................92 Stabilizing Your Processes ........................................................................94   7  Your.First.Kaizen.Project.Team..................................................97 What Is a Kaizen Event (Continuous Improvement Event)? ....................97 Team Makeup ............................................................................................98 Contents  ◾  vii Kaizen Event Process ................................................................................98 SMART Goals ..........................................................................................101 Plan–Do–Check–Act ...............................................................................107 Using Plan–Do–Check–Act and A3 ........................................................108 Kaizen Toolbox .......................................................................................112   8  Continuous.Flow.......................................................................117 Introduction .............................................................................................117 Step 1: Determine Family Mix ................................................................117 Step 2: Build First Production Cell .........................................................118 Step 3: Create Goals and Results Chart ..................................................118 Stabilizing Your Process ..........................................................................120 Standing in the Circle .............................................................................121 Standardized Work ..................................................................................122 Using Standardized Work ................................................................123 Reducing Variability ................................................................................124 Leaders’ Standard Work versus Work Instructions ................................125 Team Leader’s Standard Work ........................................................126 Manager’s Standard Work ...............................................................127 Accountability ..........................................................................................129 Daily Production Meetings .....................................................................130   9  Work.Cell.and.Factory.Layout...................................................133 Work Cell Layout .....................................................................................133 Ergonomic Design ...................................................................................134 Work Cell Material Handling Design......................................................135 10  Creating.Your.Lean.Road.Map.(Strategy.Deployment).............137 Introduction .............................................................................................137 Strategic Lean Manufacturing Plan .........................................................138 Visual Controls and Visual Management ...............................................143 Visual Management Displays and Controls ....................................143 Andon Display .................................................................................147 11  Production.Scheduling.............................................................151 Introduction .............................................................................................151 MRP and Lean Complement Each Other ...............................................152 What Finished Goods Inventory Should You Stock? .............................153 Types of Pull Systems .............................................................................156 Organizing and Controlling Finished Goods Warehouse .....................158 viii  ◾  Contents 12  How.to.Schedule.the.Production.Line.(Value.Stream)..............163 Introduction .............................................................................................163 Pacemaker Process ..................................................................................164 Efficiency versus Changeover .................................................................166 Supermarket (Warehouse) Location in the Factory ................................167 Signaling Material Withdrawal from the Market ....................................170 Batch Production Signal Kanban ............................................................172 Production Capacity versus Changeover Time ......................................173 Determining Production Lot Size ...........................................................174 Reorder Trigger Point ..............................................................................175 Working without Work Orders ...............................................................176 Labor and Material Accuracy ..................................................................176 Work- Order Back- Flushing .....................................................................177 Cycle Count Inventory ............................................................................177 13  Material.Management...............................................................179 Raw Material Inventory Management .....................................................179 Loading the PFEP ....................................................................................182 What Data to Input First .........................................................................185 Equations Used with the PFEP ...............................................................185 Planning Minimum Inventory Levels .....................................................186 Value of Frequent Deliveries ..................................................................186 Quantity of Containers Required............................................................187 Material Reorder Points ...........................................................................187 Updating and Editing the PFEP ..............................................................187 Creating the Raw Material Market ..........................................................189 Organizing the Warehouse .....................................................................190 Layout of the Supermarket ..............................................................191 Creating the Supermarket ...............................................................192 How Do I Expedite Parts? ......................................................................192 Timed Delivery Routes ...........................................................................193 Basic Material Handling Information .....................................................194 Creating Your Timed Delivery Routes ............................................195 Point- of- Use Rack Design ................................................................196 Pull Signal for Material ....................................................................198 Coupled versus Decoupled Routes: What Is the Difference? .........198 Determining the Number of Pull Signals .......................................199 Kanban- in- the- Loop ........................................................................200 Sustaining the Material Handling System ...............................................201 Contents  ◾  ix Supplier Replenishment to Your Warehouse..........................................201 Getting Started .................................................................................202 Finished Goods Replacement .........................................................205 Tying Finished Goods Warehouse to the Production Floor ..........205 Packaging Schedule Board .....................................................................206 How to Use the Packaging Schedule Board ..................................206 Sequence of Operation ...................................................................207 14  Standardized.Problem-.Solving.Method....................................211 Problem Solving ......................................................................................211 Recognize You Have a Problem .....................................................212 Elevate to the Next Higher Level ....................................................212 Evaluate the Severity of the Problem .............................................212 Control the Expansion of the Problem ...........................................212 Containing the Problem ..................................................................213 Preventing a Recurrence .................................................................213 Inspect Every Job ............................................................................214 Mistake- Proofing .....................................................................................215 Where Do You Start Error- Proofing? ..............................................217 General Inspection ..................................................................218 100% Inspection ......................................................................219 Error- Proofing Devices ............................................................219 Immediate Feedback ...............................................................220 Statistical Process Control and Mistake- Proofing ...........................221 15  Working.with.Suppliers.and.Partners......................................223 Introduction .............................................................................................223 Looking for Suppliers ..............................................................................224 Seven Characteristics of Supplier–Customer Partnering ........................225 Outsourcing Products .............................................................................228 Group Suppliers by Capability ................................................................229 16  Lean.Accounting.......................................................................231 Show Me the Money ...............................................................................231 Performance Goals ..................................................................................232 Box Scores ...............................................................................................233 What You Get for Your Effort .................................................................236 Profit and Loss (Income) Statements ......................................................236 Cash- to- Cash Cycle .................................................................................241 Calculate Cash- to- Cash Cycle ..........................................................242

See more

The list of books you might like

Most books are stored in the elastic cloud where traffic is expensive. For this reason, we have a limit on daily download.