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MSE507 Lean Manufacturing

MSE507 Lean Manufacturing. Chapter 1 Customer Value. "There is only one boss: the customer. And he can fire everybody in the company, from the chairman on down, simply by spending his money somewhere else." Samuel M Walton. Key Point . Value is defined by the customer.

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MSE507 Lean Manufacturing

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  1. MSE507Lean Manufacturing Chapter 1Customer Value "There is only one boss: the customer. And he can fire everybody in the company, from the chairman on down, simply by spending his money somewhere else." Samuel M Walton

  2. Key Point • Value is defined by the customer Whenever there is a product for a customer, there is a value stream. The Challenge lies in seeing it…

  3. Module Goals • Know • Your external customers • Your internal customers • Feel • Capable of talking to your customer • Do • Identify what your customers value • Measure the delivery of value to your customers

  4. Profitable SalesGrowth Customer Satisfaction Functional Silos Quality Delivery Voice of The Customer Cost Control SCM Customer Service Engineering Manufacturing Administration Sales Design ResultsProfitable Sales Knowing what your customers value enables you to… • …build loyalty - penetrate deeper, retain more longer • …win new accounts - keep them • …make transactions easier, faster • …add services, support - higher value • …develop new products, services - higher value • …enhance marketing programs • …help customers succeed

  5. What do Customers Value? • The technical performance or quality of a product is no longer the primary determinant of customer value. • Customers evaluate other "value factors“ such as: • Delivery • Total cost of ownership • Data and information • Value or solution bundles • Business expertise • What does your customer value? • More importantly, what are you doing about it?

  6. 7 Types of Waste

  7. 7 Types of Waste • Overproduction - The primary waste • Making parts faster than is required • Excess Inventory • Time wasted, that could be used to make product that is required • Waiting • An operator waiting for a long machine cycle to end • Transportation • Moving parts and products does not add value - it just adds cost

  8. 7 Types of Waste • Unnecessary Processing • Booking work into a store and then having to book it back out again to use. • Inventory • There is a cost to the Company for carry inventory • There is always the risk it can become obsolete • It covers up other inefficiencies e.g. Long set-up times

  9. 7 Types of Waste • Unnecessary Motion • Any motion of a person that does not add value • Operators / Setters looking for tooling • Correction • Reworking defective materials • Things to remember about waste • It is a symptom rather than a root cause of the problem • It points to problems within the system, at both process and value stream levels • We need to find and address the causes of the waste

  10. Identify Customer Value Understand and Define Entire Value Streams Vision (Strategic Business Plan) Deploy Key Business Objectives - Measure and target (6 metrics) - Align and involve all employees - Develop and motivate Continuous Improvement (DMAIC) Define, Measure, Analyze, Improve Identify root causes, prioritize, eliminate waste, make things flow and pulled by customers Control -Sustain Improvement -Drive Towards Perfection Basic Roadmap

  11. CautionsNever, ever assume that… • You already know what the customer wants. • Marketing and sales people “know the customer” • Unless they have a defined program of regularly asking the customer what they want. • Customer’s requirements are the same as always • They will change over time • We need to monitor and track • You understand why customers do what they do. • What drives them? • Ask customers directly; do not assume you know.

  12. Quiz TimeDo you… • Have management commitment and involvement? • Have a defined list of your customers? • Ask your customers what they value? • Ask your customers the importance of those values? • Ask your customers how you perform? • Map the flow of value to the customer? • Measure your performance in delivering value? • Know how your performance affects the company? • Know your competitive advantage? • Use this information to prioritize OpEx projects? • Have a defined program for continuous improvement?

  13. Basic Plan • Identify your customers • Ask the customers what they value • Map your value stream • Measure the delivery of value • Make continuous improvements

  14. Identify Your Customers • External • Consumers • Distributors • OEMs • Internal • Next process • Shipping • Management • Inspection/audit • Other • Employees • Suppliers

  15. Be Customer Focused • Make a list of all customers • Put the list in order of priority to your process • The most important customer is often the next process • Post the list in the work area • Be aware of all customers

  16. Ask the CustomerAsk Yourself 3 Questions • What do you want to know? • Who do you want to know it from? • What are you going to do with the information? • If you cannot answer question 3, you should not bother asking questions 1 and 2.

  17. Ask the CustomerGeneral Questions • What is most important to them? • What would ‘make their day’? • What would utterly delight them? • What would differentiate you from the competition? • Use open-ended questions.

  18. Ask the CustomerStandard Questions • How important to you is [OTD]? • What do you mean by [OTD]? • How do we perform on [OTD]? • What do you do if we don’t perform? • What impact does non-performance have on you? • Ask for each factor of interest to you. • Use a scale of 1 (low) to 9 (high)

  19. Ask the CustomerProcess • Openly state your purpose for asking questions • Do more listening than talking • Do not be defensive, take criticism graciously • Probe for explanations; ask “why” five times • Do not try to ‘sell’ the customer, just gather data

  20. Ask the CustomerReport Findings – 2x2 Grid

  21. Map Your Value Stream

  22. Measure the Delivery of Value

  23. Make Continuous Improvement

  24. Class Exercise - Customer Interview • Pair up • Scenario 1 (two minutes) • Person A (customer) – is interested in a new car • Person B – find out what Person A values in a new car • Scenario 2 (two minutes) • Person B (customer) – is selecting a restaurant to eat at • Person A – find out what Person B values in a restaurant • Group discussion • Any surprises? • Any difficulties?

  25. SPECIFY VALUE 1 IDENTIFY THE VALUE STREAM 2 4 CONVERT PUSH TO PULL 3 FLOW Lean Manufacturing Cycle • Step 5 – CONTINUOUSLY IMPROVE • Getting value to flow faster exposes hidden muda in the value stream. • The harder you pull, more obsticles to flow are revealed so they can be removed.

  26. Integrating the Lean Enterprise

  27. Homework Assignment • What is considered as value in the eyes of customers. Why? • What are the seven types of waste? Give examples for each one. • Read Lean Thinking Chapter 2 • The Value Stream • Pages 37-49

  28. Questions? Comments?

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