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VadiK teachings Vadim Kotelnikov

Lean Production

Ultimate efficiency

Vadim Kotelnikov, founder of 1000ventures - personal logo VadiK

Inventor Business e-Coach

Author Innoball

Founder Innompic Games icon

 
7 Wastes 3 Broad Types of Wastes Transitioning To a Lean Enterprise: Kore 10 Tips Creating Sustainable Value CReating Customer Value 80/20 Principle and Continuous Improvement Business e-Coach Lean Production / Lean Manufacturing - Doing More With Less  

Lean is about doing more with less: less time, inventory, space, labor, and money. 

Lean manufacturing is about commitment to eliminating waste, simplifying procedures and speeding up production. The idea is to pull inventory through based on customer demand.

  

 
 

Lean Manufacturing – also known as the Toyota Production System (TPS) – is, in its most basic form, the systematic elimination of waste – overproduction, waiting, transportation, inventory, motion, over-processing, defective units – and the implementation of the concepts of continuous flow and customer pull. By continually focusing on waste reduction, lean enterprises can achieve unlimited benefits.

Five areas drive lean manufacturing: cost, quality, delivery, safety, and morale.

Value is defined by the ultimate customer’s needs.

 		 

Continuous Improvement Firm (CIF)

Kaizen and Lean Manufacturing

Kaikaku-Kaizen Journey

Implementation

Suggestion System

Examples of CIF

  

 

 

 
 

Management Philosophy

Toyota perfected lean manufacturing in the 1990s, and now the concept is being put to use in other areas, such as organizational structures, distribution and logistics.

Though books have been written detailing the steps to achieving lean manufacturing and many manufacturers have tried to emulate Toyota's success, few have actually done so. Why? Because they have failed to adopt lean manufacturing as a management philosophy that encompasses the entire organization. Instead, they see it only as a departmental solution.

Toyota's management philosophy is enterprise-wide. Toyota states: "...based on the concept of continuous improvement, or Kaizen, every Toyota team member is empowered with the ability to improve their work environment. This includes everything from quality and safety to the environment and productivity. Improvements and suggestions by team members are the cornerstone of Toyota's success."

 

Kaizen

6Ws

Kaizen Mindset

7 Conditions

Kaizen Practices

Kaizen and TQM

Lean Manufacturing

Toyota Production System (TPS)

Canon PS

Characteristics of Lean Manufacturing Systems

Applications of Lean: Lean Techniques, Lean Thinking, Lean Startup

  

 

 

 

 

 

  

 

 

 

Lean System Components and Best Practices

  1. Cultural awareness

  2. Workplace organization – 5S (sort – straighten – sweep – standardize – self-discipline) & visual control

  3. Standardized work

  4. Flexible operations

  5. Employee empowerment and continuous improvement

  6. Quick changeover capability

  7. Total quality management & total productivity maintenance

  8. Error proofing

  9. Material control

  10. Level production

7 Principles of Toyota Production System (TPS)

  1. Reduced Setup Times

  2. Small-Lot Production

  3. Employee Involvement and Empowerment

  4. Quality at the Source

  5. Equipment Maintenance

  6. Pull Production

  7. Supplier Involvement... More

→ The Toyota Way: 14 Principles

 

Key Features of Lean Production

 compared to Traditional Mass Production

  • Reduced Setup Cost and Times (for semi-versatile machinery such as big stamping presses) – from months to hours thus making small-lot production economically viable; achieved by organizing procedures, using carts, and training workers to do their own setups,.. More

  

Strategy of Lean Production
 

Lean Manufacturing

Lean vs. Traditional Manufacturing

3 Broad Types of Wastes  ●  7 Wastes

 

Efficiency Improvement

 

Continuous Improvement Firm (CIF)

3 Basic Principles

Kaizen – the Japanese Strategy of Continuous Improvement

Quick and Easy Kaizen

Kaizen and Total Quality Management (TQM)

Kaizen and Radical Innovation

The Toyota Way: 14 Principles

Glossary – Kaizen & Lean Production

Suggestion Systems

Japanese  ●  Fun4Biz

Value Chain Management

Employee Empowerment

Supply Chain Management

E-business

ERP  ●  EDI

Lessons from Winners

Toyota Production System (TPS)  >>  7 Principles

Gold Seal  ●  Rojee Tasha  ●  Thara Engineering

JIT Implementation

Benefits of Lean Production

Establishment and mastering of a lean production system would allow you to achieve the following benefits:

  • Waste reduction by 80%

  • Production cost reduction by 50%

  • Higher → quality

  • Manufacturing cycle times decreased by 50%

  • Labor reduction by 50% while maintaining or increasing throughput

  • Inventory reduction by 80% while increasing customer service levels

  • Capacity in current facilities increase by 50%

  • Higher → profits

  • Higher system flexibility in reacting to changes in requirements improved

  • More strategic focus

  • Improved cash flow through increasing shipping and billing frequencies

However, by continually focusing on waste reduction, there are truly no end to the benefits that can be achieved.

→ Kaizen: 5 Principles

→ Kaizen Culture: 8 Key Elements

→ Implementing Kaizen: 7 Conditions

Characteristics of Lean Manufacturing Systems

  • Close integration of the whole → value chain from raw material to finished product through partnership oriented relations with suppliers and distributors.

  • → Team based work organizations with multi skilled operators empowered to make decisions and improve operations with few indirect staff... More

Case Studies Toyota

Toyota’s global → competitive advantage is based on a corporate philosophy known as the Toyota Production System. The system depends in part on a human resources management policy that stimulates employee creativity and loyalty but also on a highly efficient network of suppliers and components manufacturers... More

The Toyota Way is not the Toyota Production System (TPS). The 14 Principles of the Toyota Way is a management philosophy used by the Toyota corporation that includes TPS, also known as lean manufacturing... More

Case Studies Three Small- and Medium-Sized Firms, U.S.A.

Smaller and mid-sized organizations pride themselves on being nimble – quick to respond and to seize opportunities. Many believe smaller size is more manageable; and that internal communications in a smaller group can be maintained so employees can take ownership of more than their own corner of the enterprise. One key to success is maximizing resources and discovering inventive ways to overcome budget limitations. Another trend is moving from a PUSH system – building to forecasts – to a PULL system, building in response to orders... More

    Continuous Improvement Firm (CIF) CIF Implementation Kaikaku (Radical Improvement) Kaizen (Continuous Incremental Improvements) Customer-focused TQM Kaizen and TQM 3 Pillars of Kaizen Continuous Imprivement Culture: Japan vs. the West Kaizen Best Practices CIF Best Practices Amazing Thinker Kaizen Implementation Principles Suggestion Systems 7 Conditions for Successful Implementation of Kaizen Strategt Kaizen Culture: 8 Elements Kaizen Continuous Imprrovement Firm (CIF): Mindset, Culture, Systems 

References:

  1. Relentless Growth, Christopher Meyer

  2. "Competitive Manufacturing Management", John M. Nicholas

  3. "The Lean Journey" White Paper by Oracle Corporation

  4. "TPS vs. Lean and the Law of Unintended Consequences," Art Smalley

  5. "Lean Thinking," James Womack and Daniel Jones

  6. Lean Manufacturing That Works, Bill Carreira

  7. The Toyota Way, Jeffrey Liker

  8. Toyota Production System,, Taiichi Ohno

  9. "Kanban Just-In-Time at Toyota," Japan Management Association

  10. "Lean Production Simplified," Pascal Dennis, John Shook

  11. "The Lean Manufacturing Pocket Handbook," Kenneth W. Dailey

  12. "Lean Six Sigma," Michael L. George

  13. Kaikaku: The Power and Magic of Lean, Norman Bodek