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Lean Manufacturing Consulting Program
What is Lean?
In its most basic of concepts, Lean is the relentless
removal of wasteful activities. Jim Womack, in his book
"Lean Thinking," states it is determining what is of
value and then making it flow. Determining what is of
value is simple; the customer makes that decision.
Making it flow is quite another thing. |
What is "Lean Manufacturing"?
The term "Lean Manufacturing" is the prosecution of
lean activities including each process from taking the
order to collecting the cash. If the organization
conducts design activities, then it begins with concept
through design, launch, production, shipment, and
service. The entire path consists of processes, some
connected and some not. Each becomes the subject for
the exhaustive reduction of waste.
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What are wasteful activities?
Waste can be found in all processes. Some of the major categories of waste are:
- Overproduction
- Inventory
- Transportation
- Waiting
- Motion
- Overprocessing
- Correction
- Not utilizing the talent and knowledge of human resources
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Where does it begin?
The old saying, "You get what you measure and you
measure what you value" sums it up. With Lean we
generally measure what others ignore and ignore what
others measure. The critical component is, "It makes no
sense to run the shop floor with financial
measurements." Systems of variance, ROI, labor reporting and absorption must give way to "Lean
Performance Measurements." Lean measurements
must be in real time, so quick reaction is possible.
Measurements should include product velocity, quality,
machine utilization, and Takt Time.
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Lean Manufacturing and Six Sigma.
When Lean Initiatives are organized, one problem after
another will surface. Problems will be identified
regarding set-up times, quality, rework / scrap,
capacity, flow, balance, lack of stability, etc. To this end,
the application of Six Sigma methods has no equal. The
Six Sigma discipline of Define, Measure, Analyze,
Improve, Control is the most exhaustive set of problem
solving tools ever assembled. Additionally, the power of
Six Sigma lies in certified practitioners, such as Yellow,
Green, Black and Master Belts. It is quite clear that the
integration of Lean and Six Sigma will deliver the
promise of wealth and prosperity within any company.
SAI Global can help deliver on this promise with
training programs to plan and implement your lean
program and consulting support including our
innovative Assessment for Lean Manufacturing.
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