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    ME 410 Lecture Slides 03

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    bilal liaquat
    This document provides an overview of lean methodology tools and principles for implementing lean manufacturing. It discusses lean building blocks like kaizen, pull systems, standardized work, and visual management. Kaizen methodology is described as an 8 step continuous improvement process. Other lean tools explained include the 5 Whys for root cause analysis, fishbone diagrams for cause-and-effect relationships, spaghetti diagrams for workflow analysis, and 5S scorecards for evaluating application of 5S principles.

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    ME 410 Lecture Slides 03

    Uploaded by

    bilal liaquat
    15 views8 pages
    This document provides an overview of lean methodology tools and principles for implementing lean manufacturing. It discusses lean building blocks like kaizen, pull systems, standardized work, and visual management. Kaizen methodology is described as an 8 step continuous improvement process. Other lean tools explained include the 5 Whys for root cause analysis, fishbone diagrams for cause-and-effect relationships, spaghetti diagrams for workflow analysis, and 5S scorecards for evaluating application of 5S principles.

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    This document provides an overview of lean methodology tools and principles for implementing lean manufacturing. It discusses lean building blocks like kaizen, pull systems, standardized work, and visual management. Kaizen methodology is described as an 8 step continuous improvement process. Other lean tools explained include the 5 Whys for root cause analysis, fishbone diagrams for cause-and-effect relationships, spaghetti diagrams for workflow analysis, and 5S scorecards for evaluating application of 5S principles.

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    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    15 views8 pages

    ME 410 Lecture Slides 03

    Uploaded by

    bilal liaquat
    This document provides an overview of lean methodology tools and principles for implementing lean manufacturing. It discusses lean building blocks like kaizen, pull systems, standardized work, and visual management. Kaizen methodology is described as an 8 step continuous improvement process. Other lean tools explained include the 5 Whys for root cause analysis, fishbone diagrams for cause-and-effect relationships, spaghetti diagrams for workflow analysis, and 5S scorecards for evaluating application of 5S principles.

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    You are on page 1of 8

    Lecture 3: Overview

    1. Lean Methodology and Building Blocks


    2. Kaizen Methodology
    3. The 5 Whys
    4. Fishbone Diagram
    5. Spaghetti Diagram
    6. 5S Scorecard

    Principles for Implementing Lean Manufacturing


    Definition of Lean
    “A systematic approach to identifying and eliminating waste (non-
    value-added activities) in a company’s operations.
    Lean emphasizes flowing the product at the pull of the customer.”
    Lean is implemented through both rapid and continuous
    improvement.
    Kaizen- “kai’ means “little” or “ongoing”. “Zen” means “for the
    better” or “good.” Small continuous improvements on everyone’s
    part leads to world class manufacturing.

    Principles for Implementing Lean Manufacturing


    Lean Building Blocks

    KAIZEN

    Pull/Kanban Cellular/Flow TPM

    Quality at Source POUS Quick Changeover

    Standardized Work Batch Reduction Teams


    Value
    5S System Visual Plant Layout Stream
    Mapping

    Principles for Implementing Lean Manufacturing


    Kaizen Methodology
    1. Select project/opportunity
    2. Study design principles/best practices from previous
    projects
    3. Prepare an analysis of the current state
    4. Generate proposed solutions (future state)
    5. Develop proposed solution
    6. Get feedback on proposed solution
    7. Revise and implement solution
    8. Measure impact
    9. Disseminate
    5 Whys
    Question asking method used to discover
    root cause of a problem
    • Highlights cause – effect relationship
    • Identify problems – not just symptoms
    • Have to ask the right why questions
    • Could be any number of whys
    Example:
    • My car will not start. (the problem)
    • Why? - The battery is dead. (first why)
    • Why? - The alternator is not functioning. (second why)
    • Why? - The alternator belt has broken. (third why)
    • Why? - The alternator belt was well beyond its useful service life and has
    never been replaced. (fourth why)
    • Why? - I have not been maintaining my car according to the recommended
    service schedule. (fifth why, root cause)
    Excerpt from Wikipedia
    Fishbone (Ishikawa) Diagram
    A cause and effect diagram that highlights
    the relationships and types of causes

    Image from Wikipedia

    Example: http://www.techrepublic.com/article/use-a-fishbone-diagram-to-help-attack-complex-problems/
    Spaghetti Diagram
    Chart that shows the flow of product –
    highlights inefficiencies in layout

    QC Ship
    Rec
    Raw Stock

    Screw QC
    Shear Stamp Machine

    Lathe Drill
    Brake Assembly
    Mill

    Weld Grind Finish Parts Stock


    5S Scorecard
    Checklist to evaluate current status of 5S
    application and guide future application
    of 5S

    http://www.slideshare.net/bengeck/
    5sauditscorecard
    https://
    kalispellchamber.files.wordpress.com
    /2009/03/office-5s-scorecard-
    preferred.pdf
    http://
    www.leanhealthcareexchange.com.php5-
    16.dfw1-1.websitetestlink.com/
    wp-content/uploads/2009/08/5S-
    Scorecard.pdf

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