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Lean Techniques

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Balan Venkatramani

on 2 October 2017

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Transcript of Lean Techniques

Lean Techniques - an introduction
'Perfection is not attainable. But if we chase perfection, we can catch excellence.'
Vince Lombardi
1799 - Eli Whitney - Interchangeable parts - muskets
1803 - Isambard Brunel - created FLOW - Block-making for Royal Navy
1835 - Samuel Colt removed WASTE
1900 - Frank Gilbreth - PROCESS CHARTING
1910 - Henry Ford - CONTINUOUS FLOW
1924 - Walter Shewhart - PROCESS CONTROL CHART
1940 - James Edward Deming - QC Methods
1948 - Taichi Ohno - Start of redesign of Ford Manufacturing Systems
1950 - James Edward Deming - Lecture on QC to top 400 Japanese Industrialists
1950 - SMED
1960 - KANBAN
1973 - JIT
1980 - NBC - Documentary on 'If Japan can, Why Can't we'
1998 - John Krafcik - Coins LEAN - "Triumph of the Lean Production System,"
1991 - Roos, Daniel, Ph.D.; Womack, James P., Ph.D.; Jones, Daniel T.:
The Machine That Changed the World : The Story of Lean Production
Definition

DO MORE WITH LESS
3Ms
The COKE Can
MUDA
The Journey
History
Give the customer what they want, when they want it at a price and time at which they want it
The core idea is to maximize customer value while minimizing waste
TPS
3Ms
1. Muda associated with
waiting
2. Muda associated with
transport
3. Muda associated with large
inventories
4. Muda associated with
processing

5. Muda associated with
movement
6. Single line:
inelastic

7. Single line:
underutilised

MURA
Inconsistency caused by Variability
Standardisation.... is the necessary foundation on which tomorrow's improvement will be based.

Henry Ford
MURI
5 S
Sort
Set
Shine
Standardise
Sustain
Sort
Retain
Return
Rid
Set
Organise
Arrange
Store
Shine
Clean
Appearance
Standardise
Regular work routine
Maintain first 3S
Sustain
Sustain the 5S practice
Make it an organisation wide practice
KAIZEN
Remember the Objective
Kanban
Signboard or Billboard
Scheduling system for Lean and JIT
Value Stream Mapping
VSM
- Analysis of the events that take a product/service from start to
customer
.
Significant part of Lean
WHO IS YOUR CUSTOMER?
Internal
External
Customer
Value as Perceived by the Customer
To Summarise
What is Lean?
TPS = 5%
Kanban = 15%
Waste Elimination = 80%
What Can You Do In Construction?
109 million tons of waste/year; (24% of total UK waste)
13% delivered and unused; 36 million tons to landfill/year

Nobody Does it Better!
Modern Approaches to Construction
REMEMBER
5 PRINCIPLES OF LEAN
1. Specify Value
2. Identify Value Stream
3. Flow
4. Pull
5. Perfection
FLOW
Significantly Improve:
1. Quality
2. Productivity
3. Client satisfaction
IMPORTANTLY REDUCE WASTE IN ALL FORMS
Full transcript