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Effective Lean Implementation Techniques to Achieve Bottom Line Results

Effective Lean Implementation Techniques to Achieve Bottom Line Results. Presented By Baskar Kotte Quality Systems Enhancement, Inc. 1790 Woodstock Road Roswell, Georgia 30075 Toll Free : 1-866-577-4476 baskar@enhancequality.com www.enhancequality.com. Lean: The QSE Focus. Lean.

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Effective Lean Implementation Techniques to Achieve Bottom Line Results

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  1. Effective Lean Implementation Techniques to Achieve Bottom Line Results Presented By Baskar Kotte Quality Systems Enhancement, Inc. 1790 Woodstock Road Roswell, Georgia 30075 Toll Free : 1-866-577-4476 baskar@enhancequality.com www.enhancequality.com

  2. Lean: The QSE Focus Roswell, Georgia info@enhancequality.com 1-866-577-4476

  3. Lean • Not just lean manufacturing • Lean is an enterprise • Lean enterprise covers all areas of business Roswell, Georgia info@enhancequality.com 1-866-577-4476

  4. Lean Enterprise Focus • Achieve more with less • Minimize inventory at all stages of production • Improve machine efficiency and delivery performance • Eliminate waste of all kinds (time-material) • Error-proof process with problem solving techniques • Reduce purchasing cost and customer credits • Improve information system • Improve quality and customer satisfaction Roswell, Georgia info@enhancequality.com 1-866-577-4476

  5. Definition of Lean Enterprise • Lean enterprise is a balanced organization Discipline Problem solving Empowered Employees ISO Roswell, Georgia info@enhancequality.com 1-866-577-4476

  6. Definition of Lean Enterprise • Causes of failure Not my job I am the Boss No discipline No problem solving No commitment Roswell, Georgia info@enhancequality.com 1-866-577-4476

  7. Lean Tool Mumbo Jumbo • Production leveling / smoothing • Point-of-use systems • Kanban • Kaizen • Single Minute Exchange of Dies (SMED) • Standardized work • Statistical Problem Solving (SPS) • Balanced Scorecard • Value stream mapping • Quality at the source • Workplace organization: 6S • Total Productive Maintenance (TPM) and Overall Equipment Effectiveness (OEE) • Visual management • Batch size reduction • Cellular manufacturing • Work balancing (TAKT-time) Roswell, Georgia info@enhancequality.com 1-866-577-4476

  8. Lean Tools for the Box Industry • Value stream mapping • 6S • Visual management • Statistical Problem Solving (SPS) techniques • Total Productive Maintenance (TPM) and Overall Equipment Effectiveness (OEE) • Work balancing (TAKT-time) • Kanban • Kaizen • Single Minute Exchange of Dies (SMED) Roswell, Georgia info@enhancequality.com 1-866-577-4476

  9. Understanding Selected Tools and Techniques: Value StreamMapping How long does it take for value stream mapping? • 6 weeks? • 4 weeks? • 1 week? If it takes more than 4 hours, then we are wasting our time Roswell, Georgia info@enhancequality.com 1-866-577-4476

  10. Quote Quote to Cash Value stream map • Understanding the process • steps • Picking the process which has • more $$ value impact • Picking right tools Cash This flow diagram required for ISO as well Roswell, Georgia info@enhancequality.com 1-866-577-4476 10

  11. Understanding Selected Tools and Techniques: OEE Overall Equipment Effectiveness = Availability % x Performance % x Quality% x 100 Roswell, Georgia info@enhancequality.com 1-866-577-4476

  12. Understanding Selected Tools and Techniques: OEE Understanding Selected Tools and Techniques: OEE Production Time – Down Time Available Time 480 mins. – 60 mins 480 A= X 100 = 87% X 100 = # of Boxes Produced Actual Machine Run Capability % 8,000 10,000 P= X 100 = 80% X 100 = Good Boxes Total # of Boxes Run 98,000 100,000 Q= X 100 = 98% X 100 = A= availability P= performance Q= quality OEE= A x P x Q x 100 .87 x .80 x .98 x 100 = 68.2 % Roswell, Georgia info@enhancequality.com 1-866-577-4476

  13. Understanding Selected Tools and Techniques: TAKT Time TAKT time is the rate at which customers require the product TAKT time is computed as: Available work time per day(480-BREAKS) Daily required customer demand in BOXES per day Roswell, Georgia info@enhancequality.com 1-866-577-4476

  14. Understanding Selected Tools and Techniques: Visual Management • Charts • Metrics • Procedures • Process documentation Roswell, Georgia info@enhancequality.com 1-866-577-4476

  15. Understanding Selected Tools and Techniques: Quick Setups • SMED • Effective implementation of 6S • Machine center lining, zero gear trains, time and register • Standardization of cutting dies and printing plates Roswell, Georgia info@enhancequality.com 1-866-577-4476

  16. Understanding Selected Tools and Techniques: Kanban • A pull material replenishment system, based on the principle that material is pulled through the production process based on actual usage of material • Kanban uses visual signals, usually a card, to move material through the value chain Roswell, Georgia info@enhancequality.com 1-866-577-4476

  17. Understanding Selected Tools and Techniques: Kaizen • Continuous improvement through incremental improvement • The whole secret to Kaizen is to create an atmosphere, a culture of continuous improvement, by focusing on problems not on people . • Kaizen compliments the other tools of Lean and it is part of a whole rather than a stand-alone process Roswell, Georgia info@enhancequality.com 1-866-577-4476

  18. Lean Tools and Techniques:Statistical Problem Solving The steps of Statistical Problem Solving • Defining the problem • Listing suspected variables • Prioritizing variables using subjective rating • Evaluating the critical few variables by conducting studies and trials • Optimizing variable settings Roswell, Georgia info@enhancequality.com 1-866-577-4476

  19. QSE’s Approach to Cost Reduction • Quotation to cash • Follow the money • Application of disciplined problem solving • Top 5 $$$ impacting items Roswell, Georgia info@enhancequality.com 1-866-577-4476

  20. Example Problems Picked By Our Customers – Maximum $$$ Impacting Bottom Line • Excessive inventory (wip, ink, sheets, finished goods) • Purchasing (cost of raw materials, uncontrolled purchasing methods) • Set up time reduction • Over runs • Supplier sheets (defects) • Estimation, quotes time • Incomplete information on RFQs • Incorrect customer specs • Maintenance parts inventory (old obsolete, doubled up parts) • Ineffective or non-existing procedures and instructions Roswell, Georgia info@enhancequality.com 1-866-577-4476

  21. QSE’s Proven Lean Implementation Guidance • Recognize lean as a long term journey • Recognize obstacles to change • Adequate resource allocation • Focus on both manufacturing and non manufacturing areas Roswell, Georgia info@enhancequality.com 1-866-577-4476

  22. QSE’s Proven Lean Implementation Guidance • Benchmark but do not copy • One system • Synchronize lean goals with business goals • Empowerment / team approach • Create an atmosphere, a culture of continual improvement Roswell, Georgia info@enhancequality.com 1-866-577-4476

  23. Defined Path for Effective Lean Implementation 1.Lean Tools and concepts training 2. Baseline assessment/establishment of goals and metrics 3. Selection of appropriate lean tools and concepts Roswell, Georgia info@enhancequality.com 1-866-577-4476

  24. Defined Path for Effective Lean Implementation 4. Train the implementation team for the application of the selected tools and concepts 5. Assist in the application of the selected tools and concepts Roswell, Georgia info@enhancequality.com 1-866-577-4476

  25. Defined Path for Effective Lean Implementation 6. Monitor and audit improvement against goals, re-evaluate the process if necessary 7. Fine-tuning of the processes to achieve value-added results Roswell, Georgia info@enhancequality.com 1-866-577-4476

  26. Defined Path for Effective Lean Implementation 8. Maximize/optimize implementation effectiveness for bottom line improvement 9. Incorporate results into standardized procedures 10. Management review of accomplished results Roswell, Georgia info@enhancequality.com 1-866-577-4476

  27. Effective Lean Implementation: QSE Difference • Not just promise – GUARANTEED 15% waste reduction from baseline assessment • Not just train – ASSIST in implementation • Not just manufacturing – ALL non manufacturing areas of the business Roswell, Georgia info@enhancequality.com 1-866-577-4476

  28. Effective Lean Implementation: QSE Difference Not just problem identification – ASSIST in systematic problem solving Not just team building – TRAIN the team in problem solving techniques Roswell, Georgia info@enhancequality.com 1-866-577-4476

  29. Effective Lean Implementation: QSE Difference • Not just lean, COMBINE ISO, lean and problem solving to sustain bottom line results • Integrate all lean procedures and instructions into one manageable simplified ISO process approach • Audit lean results for sustainability integrated with ISO auditing techniques Roswell, Georgia info@enhancequality.com 1-866-577-4476

  30. Successful Lean Implementation • No lean strategy will work until process is error proofed with: • Disciplined/defined path • Problem solving techniques • Simplistic ISO (if applicable) Roswell, Georgia info@enhancequality.com 1-866-577-4476

  31. Successful Lean Implementation: Integrate with ISO • One level documentation • Realistic • Practical • Internal auditing for continual improvement • Control of nonconformities • Corrective and Preventive action plans Roswell, Georgia info@enhancequality.com 1-866-577-4476

  32. Successful Lean Implementation: Problem Solving • Systematic/Statistical Problem Solving • Effective root cause analysis • Apply sustainable, permanent problem solving techniques • Problem solving is a problem Roswell, Georgia info@enhancequality.com 1-866-577-4476

  33. Effective Lean Implementation Summary • Lean Focus • Definition of Lean Enterprise • Lean Tool Selection • Understanding Selected Tools/Techniques • QSE’s Approach to Cost Reduction Roswell, Georgia info@enhancequality.com 1-866-577-4476

  34. Effective Lean Implementation Summary • QSE’s Proven Lean Implementation Guidance • Defined Path for Effective Lean Implementation • Effective Lean Implementation: QSE Difference • Successful Lean Implementation: Integrate with ISO Roswell, Georgia info@enhancequality.com 1-866-577-4476

  35. Effective Lean Enterprise Summary • Successful Lean Implementation: Problem Solving • Successful Lean Enterprise has commitment and involvement at all levels of the organization Roswell, Georgia info@enhancequality.com 1-866-577-4476

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