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1 Click to edit Master title style LEAN MANUFACTURING TRANSLATING PHILOSOPHY IN TO REALITY 1 BY S. DURAI RAJAN DIRECTOR INSTITUTE ASIA PACIFIC CHENNAI drajan@kiap.in 1

2 What is Lean Manufacturing? Click to edit Master title style Lean Manufacturing is an all encompassing culture, a behavior or mindset that focuses on the Customer. Anything that the Customer does not perceive as Adding Value is considered Waste. Lean Manufacturing seeks a Continuous Flow for all value-add process steps through the system by Elimination of Waste, thereby reducing the Time to Customer. 2 2

3 Click What to is edit Lean Master Management? title style Lean Management focuses on eliminating waste in processes Lean Management is about expanding capacity by reducing costs and shortening cycle times between order & ship date Lean Management is not about eliminating people but improving the effectiveness of the people by enabling them to do only what is needed and important to the customer both internal / external. It means doing only Value DELIVERED Work a new paradigm. 3 3

4 What is Lean? Click to edit Master title style Lean is More and More with Less and Less Central theme of Lean is Waste Elimination Less effort More output Less rejection More yield Less inventory More flow Less thruput time More orders Less delays More customer satisfaction Less investment More returns Less cost More profits Less variations More reliability 4 4

5 JOURNEY TOWARDS LEAN... PERFECTION Click to edit Master title style S u p p l i e r s QCDTE Process flow Total Employee involvement Lean Support Systems Equipment Effectiveness QCDTE C u s t o m e r s FLOW PULL SYNCH- RONIZE STRUC- TURE CREATE AND SUSTAIN Eliminate: MUDA-Losses Built up a solid basis with: Foundations Eliminate: MURI-Strain Road Map for the journey that leads your Enterprise to PERFECTION Become Aware of Current state 5 5

6 Lean Steps Click to edit Master title style 1. Define or specify value from the point of view of Customer 2. Identify the Value stream sequence of processes e.g from raw materials to final customer - 3. Make Value Flow and Reduce Lead time 4. Produce only to satisfy the PULL 5. Synchronize all processes (Perfection) 6 6

7 Click to Lean edit Steps Master - Create title a flowstyle Bring Supplier and Customer Closer 7 7

8 WORK PROCESS NEW PARADIGM Click to edit Master title style PROCESS DESIGN WORK NO WORK ACTUAL WORK UNAVOIDABLE FOR WORK AVOIDABLE IMPLEMENTA- TION OF DESIGN FLOW & DELIVER REDUCE ELIMINATE EXECUTION/ OPERATION 8 8

9 Click to edit Master title style STEPS TO LEAN STATE 1. Build the culture of continually changing and improving the processes and methods eliminating/ reducing Wastes (MUDA); Inconsistencies (MURA) and Avoidable Strains (MURI) 2. Change the behavior of the organization by digging deep into the causes for the Wastes, Inconsistencies and Strains and eliminate such causes OBSERVE AND ACT AFFIRMATIVELY. 3. Remove hurdles in the journey in the form of chronic problems and uncertainities thru our unique technique of Differential Diagnosis leading to ZERO ERROR - ACT TO PERFECT. 4. Synchronize the support and supply chain processes with throughput process to achieve PERFECTION 9 9

10 Click to edit Master title style How to make LEAN a Reality? The real POWER of LEAN can be achieved, only if we fully engage people s heads & hearts, in addition to their hands, to create habits that result in Achievement and Fulfillment

11 Click to edit Master title style Power of People-Centric Approach ALIGN - the head (Top Management) to a vision the heart (Senior & Middle Management) through inspiration the hands (Work force) to continual improvement The results are... extraordinary levels of Trust, FULFILLMENT and Performance

12 Process of Personal Change Click to edit Master title style Paradigms, Perceptions Way of Being/ Culture Thoughts, Understanding Habits Behavior 12 12

13 Process of Business Change Click to edit Master title style Paradigms, Perceptions Culture Thoughts, Understanding Systems Work 13 13

14 IN A WEEK OR LESS A NEW WAY OF LIFE Click to edit Master title style 2. I denti fy Waste 1. Observe the Process 1 0. Do I t Agai n 9. Cel ebrate 8. Make thi s the Standard 11. Move Towards Perfection 7. Measure Resul ts 3. Pl an Countermeasures 4. Real i ty Check 5. Make Changes 6. Anal yze and Act agai nst Potenti al Probl ems 14 14

15 Click to edit Master title style - Value Focused Management Paradigm VALUE ENHANCERS WASTE DRIVERS TOP MANAGEMENT MIDDLE MANAGEMENT Innovation Kaizen SUPERVISORS Standard Work Maintenance of CURRENT STATUS DEVIATION DRIVERS WORKERS TIME Developed on MASAAKI IMAI s Kaizen Flag

16 LEAN MANAGEMENT: STRUCTURE Click to edit Master title style Top Management Improve and set waste-free Processes and environment for KAIZEN design value in Middle Management / Supervisor identify wastes and losses/ improve current operations take waste out of the processes Workforce: Employees, Operators, Staff standard work and avoid waste and losses keep waste out Of the processes Support through KAIZEN Methods in all areas 16 16

17 Click to edit Master title style STANDARDISATION Wheel of improvement Quality Standard High-quality consciousness Time 17 17

18 Click to edit Master title style Standardisation - Roles and Responsibilities Establish Standards Innovation Top Management Improve Standards Kaizen Middle Management Supervisors Maintain Standards Standard Work Maintenance Employees: Operators, Staff Support through Lean Methods in all areas 18 18

19 Click to edit Master title style BEST WISHES for a BRIGHT FUTURE. Many thanks for your attention 19 19