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Superfactory ® Lean Enterprise Series

Lean Office. Superfactory ® Lean Enterprise Series. Outline. What is Lean? 5S & Visual Controls Kaizen Value Streams Pull Manufacturing Mistake Proofing Quick Changeover Six Sigma Lean Accounting Theory of Constraints Human Factors. Eight Service Industry Wastes.

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Superfactory ® Lean Enterprise Series

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  1. Lean Office Superfactory® Lean Enterprise Series

  2. Outline • What is Lean? • 5S & Visual Controls • Kaizen • Value Streams • Pull Manufacturing • Mistake Proofing • Quick Changeover • Six Sigma • Lean Accounting • Theory of Constraints • Human Factors

  3. Eight Service Industry Wastes Errors in documents Transport of documents Doing unnecessary work not requested Waiting for the next process step Process of getting approvals Unnecessary motions Backlog in work queues Underutilized employees

  4. Office Process Waste • Examples: • Too many signature levels • Unclear job descriptions • Obsolete databases/files/folders • Purchase Orders not matching quotation • Errors – typo’s, misspelling, wrong data • Waiting – for information, at meetings, etc. • Poor office layout • Unnecessary E-mails

  5. Lean vs. Traditional • Major reduction in sales-order cycle time by 59 percent (from 23 hours to 9 hours) • Engineering change-order cycle time by 91 percent (from two hours to two) • Response time to customer’s quote requests by 83 percent (from 66 hours to 11 hours) • Errors by company employees were reduced by 69 percent (Tonya, 2004)

  6. Why 5S? • To eliminate the wastes that result from “uncontrolled” processes. • To gain control on equipment, material & inventory placement and position. • Apply Control Techniques to Eliminate Erosion of Improvements. • Standardize Improvements for Maintenance of Critical Process Parameters.

  7. Waste Identification • What waste can be identified in the following photos?

  8. Visual Workplace Implementation • Develop a map identifying the “access ways”(aisles, entrances, walkways etc.) and the “action” areas. • Perform any necessary realignment of walkways, aisles, entrances. • Assign an address to each of the major action areas. • Mark off the walkways, aisles & entrances from the action areas • Apply flow-direction arrows to aisles & walkways • Perform any necessary realignment of action areas. • Mark-off the inventory locations • Mark-off equipment/machine locations • Mark-off storage locations (cabinets, shelves, tables) • Color-code the floors and respective action areas

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