Leading to Lean

The process toward becoming a Lean Enterprise proceeds on three levels through a similar sequence of activities following the Plan-Do-Check-Adjust cycle. The first level is strategic, or company-wide. The second level is plant or location oriented. The third level is process-specific within a location. At each level, an important activity to facilitate planning is to define the current condition with data - establish a measurable baseline for improvement.

Steps for the Development of the Roadmap to Lean Manufacturing

Phase 1: Specify value by Product

Only the customer can define value (Real or Perceived)

• Steps:

  Select initial implementation scope

  Define customer

  Define value - Quality, Schedule, and Target Cost

• Tools

  Quality Function Deployment QFD

• Output

  The product, customer, and value all defined so as to allow the distinction between value added and non-value added operations.

Phase 2: Identify the Value Stream

Graphic or visual display of all the systems/processes that make up a value stream as the product flows

• Steps:

  Record Current State Value Stream

  Chart Product and Information Flow

  Chart Operator Movement

  Chart Tool Movement

  Collect Baseline Data

• Tools

  Value Stream Map

  Spaghetti chart

• Output

  A value stream map that shows the entire information and production process as a system with measures of value added and waste for each process.

Phase 3 - Design Production System

• Steps:

  Develop a Future State Value Stream Map

  Identify Takt Time Requirements

  Review Make/Buy Decisions

  Plan New Layout

  Integrate Suppliers

  Design Visual Control System

  Estimate and Justify Costs

• Output

  A production system design that is ready for incremental implementation.

Phase 4 - Implement Flow

This phase marks the conversion from a batch and queue type of operation to cellular type of operation.

• Steps:

  Standardize Operations SOP

  Mistake Proof Processes Poka-Yok

  Achieve Process Control

  Implement TPM Total Productive Maintenance

  Implement Self-Inspection

  Eliminate/Reduce Waste

  Cross Train Workforce

  Reduce Set-up Times SMED

  Implement Cell Layout

  Implement Visual Controls

• Output

  Areas within the production system have implemented processes to ensure that production flow has been achieved. In this state individual areas have managed to reduce a significant amount of waste

Phase 5: Strive for Perfection

The various Lean techniques and tools implemented in earlier phases are repeated and refined taking the improvements to the next level.

• Steps:

  Standardize Operations SOP

  Optimize Quality

  Institutionalize 5S

  Institute Kaizen Events

  Remove System Barriers

  Expand TPM -

  Evaluate Against Target Metrics

• Output

  The outputs of Phase 6 are incremental, continuous, and generally supportive of the Lean transition process