FACILITATING CHANGE

Lean Manufacturing
So what is Lean?
“A philosophy that when implemented reduces the time from customer order to delivery by eliminating sources of waste in the production flow.”

“The greatest source of waste is over-production, or producing more or earlier than is needed by the next process”.

Some fundamental Lean principles:

• Make only what the customer (internal & external) wants when the customer wants it
• Develop continuous flow processing wherever possible “make one, move one”
• Develop the capability to make every part every day by minimising changeover times and lot sizes
• Facilitate learning through implementation instead of focus on classroom training. Immediate application of training in the work place.

Becoming a Lean organisation is a bit like moving to another country where the People are:
• Thinking workers
• Leaders/facilitator
• Into life-long learning v
• Flexible not specialist v
• Open to change v
• Secure

The Culture is one of:
• Openness v
• Communication
• Involvement v
• Teamwork
• Partnership
• Visible leadership
• Support and facilitation
• Risk taking

The Landscape has:
• Better views
• Flowing production
• Footprints
• Less inventory mountains
• and is Unpolluted by waste

The Transport system is:
• Less congested
• Clearly signed
• Flexible
• Reliable

The Language may be strange (e.g):
• SMED/OTED v
• TPM/PM/CBM/MP
• JIT, KANBAN
• POKE YOKE
• MUDA, JIDOKA,
• 5 Ss, 7 wastes, 5 Pillars
• KAIZEN

And Measuring Systems and Currency are unfamiliar:
• Effectiveness and efficiency
• “Good” production vs total output
• Detailed measures on waste, WIP
• High quality and low cost
• Hard and soft measures of success
• Zero defects not acceptable quality