Contents
Preface……………………………………………………………………………………….vii
Acknowledgments……………………………………………………………………….ix
About the Author…………………………………………………………………………xi
Chapter 1 Where Are My Hidden Costs?…………………………………….. 1
Travel………………………………………………………………………………….3
Inventory……………………………………………………………………………4
Motion………………………………………………………………………………..6
Waiting……………………………………………………………………………….7
Overprocessing…………………………………………………………………..8
Overproduction………………………………………………………………….9
Defects………………………………………………………………………………10
Chapter 2 Understanding Your Rhythm……………………………………. 13
Chapter 3 Genchi Gembutsu…………………………………………………….. 17
Chapter 4 5S……………………………………………………………………………. 25
Sort…………………………………………………………………………………..25
“When in Doubt, Throw It Out.”…………………………………..25
Set…………………………………………………………………………………….27
“A Place for Everything and Everything in Its Place.”…..27
Shine…………………………………………………………………………………29
“Keep It Clean.”…………………………………………………………….29
Standardize……………………………………………………………………….29
“This Is What Is Expected Every Day in Every Area.”…..29
Sustain…………………………………………………………………………….. 30
“Audit the Process to Ensure Sustainability.”………………. 30
Chapter 5 Line Balance and Yamazumi…………………………………….. 33
Variable Work Content……………………………………………………..37
Chapter 6 Rebalance…………………………………………………………………39
Leaving the Waste In………………………………………………………..41
Rebalance Removing the Waste………………………………………..41
Chapter 7 Flex Plans…………………………………………………………………45
Chapter 8 Standard Work…………………………………………………………47
Chapter 9 JIT Kitting……………………………………………………………….51
Kit Specifics………………………………………………………………………52
What Type of Kit?…………………………………………………………52
Material Delivery……………………………………………………………..54
What Type of Transportation?……………………………………..54
Workstation Design………………………………………………………….55
Designed for Kits, Tools, and Ergonomics…………………….55
Line-Side Layout………………………………………………………………56
Layout for Station and Tugger Delivery……………………….56
Supermarket Design………………………………………………………….57
Size and Layout of the Supermarket……………………………..57
Pick Lists………………………………………………………………………….60
Pick Lists and Heijunka……………………………………………….60
Material Handling Takt Times………………………………………….62
Material Handling Is Now on a Takt Time……………………62
Refining the Process………………………………………………………….65
Correcting Mistakes and Anticipating the Crash Period…………………………………………………………………65
Chapter 10 High Mix and Complexity…………………………………………67
Chapter 11 Conclusion……………………………………………………………….69
Preface
Lean is the vehicle used to achieve productivity goals, produce goods and/or services faster, with better quality and at cheaper costs. Lean is the survival of our businesses. In today’s marketplace, we compete with other factories and companies from all over the world, and even in our own backyards. Your sister plants and affiliated sites are in competition for your business!
Lean does not mean eliminating a qualified, experienced, and talented workforce. It means cutting out the waste (excessive costs) that facilities have built into their processes over time. We have to compete by reducing the cost of making our products and/or services, getting them into the market faster, and at a higher quality. That seems like a daunting task, but it’s only because you don’t know how to see your problems yet. This book will aid you in seeing the wastes, what to do once you have identified them, and how to correct them to make your facility more efficient.
Lean is not something one person or team can do alone. It is not a program you run alongside your business, it is how you run your business. Lean is a common-sense approach that is used in many industries around the globe, not just manufacturing. It is truly a journey, and you cannot expect to achieve it overnight. Remember that if you are not moving forward, you are standing still and that really means you are moving backward.
Most facilities try to improve their processes by focusing on the wrong things. This book will help you to focus on the right areas that need improvement and how to correct those issues.
Over the years I have witnessed how Lean sustains businesses for growth, saves jobs, and makes benchmark sites. The fact that you are reading this book is a sign you have accepted the challenge to move forward and become a competitive supplier of goods. For that you are to be commended. I wish you success on your Lean journey, and always remember, all we have in this world is time. Once it is gone, it is gone forever.