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  • Mon, 20 Apr 2009 07:45:07 +0000: Value Stream Mapping of a Complete Product - Lean Manufacturing

    Profile:

    Shahrukh A. Irani and Jin Zhou
    Department of Industrial, Welding and Systems Engineering
    The Ohio State University

    Introduction:

    Lean Thinking, a concept that is based on the Toyota Production System, extends continuous improvement efforts to reduce the costs of serving customer/s beyond the
    physical boundaries of a manufacturing facility, by including the suppliers, distributors
    and production system that support the manufacturing function [Womack and Jones,
    1996]. These improvements and cost reductions are achieved by eliminating the muda
    (wastes) associated with all activities performed to deliver an order to a customer. Wastes
    are defined as "all activities that consume resources (add costs to the product) but
    contribute zero value to the customer." According to Womack and Jones, there are five
    steps for implementing Lean Thinking in an enterprise: 1) Define Value from the
    perspective of the Customer, 2) Identify the Value Streams, 3) Achieve Flow, 4)
    Schedule production using Pull, and 5) Seek Perfection through Continuous
    Improvement. Womack and Jones define a Value Stream as "the set of all the specific
    actions required to bring a specific product through the three critical management tasks of
    any business: ...problem solving, ...information management, ...physical
    transformation". Alternatively, Rother and Shook define a Value Stream as "all the
    actions (both value-added and non-value-added) currently required to bring a product
    through the main flows essential to every product" [Rother and Shook, 1999, p. 3].


    Overview of Value Stream Mapping

    Value Stream Mapping (VSM) is the process of mapping the material and information
    flows required to coordinate the activities performed by manufacturers, suppliers and
    distributors to deliver products to customers. Unlike the traditional process mapping
    tools used by IE's, VSM is a mapping tool that maps not only material flows but also
    information flows that signal and control the material flows. This enhanced visual
    representation facilitates the identification of the value-adding steps in a Value Stream
    and elimination of the non-value adding steps, or wastes (muda). Using VSM, many
    OEM's and their top-tier suppliers have changed their existing facility layouts, as well as
    existing systems for material handling, inventory control, purchasing and scheduling, to
    reduce the total throughput times of orders and current levels of work-in-process (WIP)
    inventories.

    Please click here for the details:

    Value Stream Mapping of a Complete Product.pdf

     

  • Sat, 18 Apr 2009 11:37:05 +0000: Value Network Mapping (VNM) - Lean Manufacturing

    Visualization and Analysis of Multiple Flows in Value Stream Maps

    Profile:

    ZahirAbbas N. Khaswala and Shahrukh A. Irani 1
    Department of Industrial, Welding and Systems Engineering
    The Ohio State University

    Outline of this Paper

    First, the concept of Lean Thinking is introduced and reviewed. This is followed by an explanation of the basic concepts of Value Stream Mapping (VSM), with a listing of the advantages and disadvantages of VSM. Specifically, it is shown that the original VSM methodology breaks down in the case of "multiple flows in a value stream that merge" in the case of complex product BOMs. Next, the development of the proposed approach, Value Network Mapping (VNM), is explained in detail. Finally, the results from an industry project are analyzed and the potential benefits of the proposed approach are presented.

    Please click here for the details:

    Value Network Mapping (VNM).pdf

     

     

     

  • Tue, 09 Dec 2008 07:05:43 +0000: Flow of Product to Consumer - Lean Manufacturing
    factory_img07.gif
    Used with kind permission from the book:
    "Mechanism of a Factory with Illustrations"
    Published by Nippon Jitsugyo Publishing.
    by Mitsuo Matsubayashi and Hiroshi Watabe.
    Members of Waku Consulting Co. Ltd
    Please click here for the web site of Waku Consulting.
  • Tue, 09 Dec 2008 07:04:05 +0000: Flow of Material and Information through the Factory - Lean Manufacturing
    factory_img06.gif
    Used with kind permission from the book:
    "Mechanism of a Factory with Illustrations"
    Published by Nippon Jitsugyo Publishing.
    by Mitsuo Matsubayashi and Hiroshi Watabe.
    Members of Waku Consulting Co. Ltd
    Please click here for the web site of Waku Consulting.
  • Tue, 09 Dec 2008 07:00:50 +0000: Operation Flow of Whole Factory - Lean Manufacturing
    factory_img05.gif
    Used with kind permission from the book:
    "Mechanism of a Factory with Illustrations"
    Published by Nippon Jitsugyo Publishing.
    by Mitsuo Matsubayashi and Hiroshi Watabe.
    Members of Waku Consulting Co. Ltd
    Please click here for the web site of Waku Consulting.

www.lean.org

  • Thu, 15 Feb 2018 00:00:00 +0000: Ask Art: Why do you say the CEO needs to become a lean expert? - Lean News at Lean.org
    A key first step for any CEO leading a lean conversion is to call 1-800-lean-consultant to find an expert to train the VP of operations and keep the boss informed. While this makes perfect sense in traditional management thinking, lean thinking is virtually the exact opposite, writes former CEO Art Byrne. That’s why the CEO must become a lean expert to successfully lead the transformation. Here, A
  • Wed, 14 Feb 2018 00:00:00 +0000: How do I love thee? Let me count the ways – on a Valentine’s Day A3 - Lean News at Lean.org
    The question lean practitioners Tracy and Ernie Richardson get more than any other isn’t about problem-solving, takt time, standardization, or their book. It’s about their “lean” marriage.
  • Mon, 12 Feb 2018 00:00:00 +0000: But when should we use design thinking or lean thinking? - Lean News at Lean.org
    Dear Gemba CoachI read your latest and very interesting Gemba Coach column comparing design thinking and lean thinking. But when should we use each?
  • Fri, 09 Feb 2018 00:00:00 +0000: Is there a crack in the model of continuous improvement? - Lean News at Lean.org
    Is this a case of déjà vu all over again? The Wall Street Journal says the sterling reputation of “Japanese manufacturing” or kaizen, is tarnished in the wake of several quality inspection scandals. But is this a kaizen crisis or a kaizen kerfuffle that we’ve experienced before? Editor Tom Ehrenfeld sorts it out.
  • Thu, 08 Feb 2018 00:00:00 +0000: Unique Industries Continue to Share and Learn from their Common Challenges: Fall 2017 LPPD Learning Group Activity - Lean News at Lean.org
    The Lean Enterprise Institute (LEI) organized the second Lean Product and Process Development (LPPD) Learning Group event of 2017, which brought together the diverse industries of sub-sea robotics, appliances, consumer electronics, automotive research, contemporary furniture and medicine. Here are some of their learnings.

 

www.leanuk.org

  • Fri, 12 Jan 2018 00:00:00 +0000: Lean Leadership Workshops in Dublin, 2018 - Lean Enterprise Academy - The UK source for Lean Thinking and Practice
    These workshops have been designed to complement and build on each other, helping you to deepen your knowledge and understanding and develop capability through purposeful practice.   Leaders that join us for this event can look forward to increasing their effectiveness by developing a greater understanding of: What Lean Thinking really is, the common pitfalls and how to navigate them How to identify the real issues that impact business performan...
  • Mon, 03 Jul 2017 00:00:00 +0000: Deep Dive into Lean Thinking - Lean Enterprise Academy - The UK source for Lean Thinking and Practice
    All company visits will consist of: A site tour (including the manufacturing plant) Presentations by company experts from product development (e.g. managers/chief engineers/designers/engineers) Discussion with participants who will be allowed to ask questions/curiosities and discuss common challenges. Local professors will lead each visit according to their field of expertise. Discussed topics include - but are not limited to - the chief enginee...
  • Tue, 27 Jun 2017 00:00:00 +0000: Lean for Leaders - The Lean Strategy - Lean Enterprise Academy - The UK source for Lean Thinking and Practice
    Our new book The Lean Strategy addresses these questions for the first time. For the last four years Michael Balle and I have worked with a unique group of CEOs and CFOs who have all gone through several consultant led programmes and come to the conclusion they had to actively lead their Lean transformations themselves, guided by a Sensei. With the help of ex-CEO Jacques Chaize and Orest Fiume former CFO of Wiremold we were able to distil this pa...
  • Fri, 07 Apr 2017 00:00:00 +0000: Practical Standardised Work: Foundation for Improvement - Lean Enterprise Academy - The UK source for Lean Thinking and Practice
    Instead of dealing with the real problems that hindered them sustaining current or getting to the next improved level of performance, they were dealing with symptoms of problems caused by excessive variation in the work.  For example, one organisation had done some great work but internal performance losses were still very high, through closer observation and basic questions we found that high setup and running losses were contributing to this lo...
  • Fri, 31 Mar 2017 00:00:00 +0000: Congratulations to our Chairman Professor Daniel T Jones - Lean Enterprise Academy - The UK source for Lean Thinking and Practice
    Professor Jones said “Lean thinking has been central to the Best Factory of the year awards in Germany over the last 25 years. This surprise Lifetime Achievement Award confirms that lean thinking has had a much more profound impact on German industry that I realised. Lean is also shaping their debate about the digital challenge and smart automation with Industry 4.0.” Congratulations also to the overall winner of the Fabrik des Jahres was ASM Ass...

 


leanmanufacturingtools.org

  • Wed, 02 Nov 2016 09:16:46 +0000: Lean Consulting and Support - Lean Manufacturing Tools

    Not every business or up and coming lean facilitator has the money to pay a consultant potentially thousands of dollars a day to come and provide the help and support that they are looking for. Nor do they necessarily want…

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  • Wed, 02 Nov 2016 09:13:05 +0000: One on One Lean Coaching Online - Lean Manufacturing Tools

    One on One Support Improving your processes can be difficult if you do not know where to start, as can be implementing Lean Manufacturing Tools such as 5S or Value Stream Mapping. Our online coaching for Lean however could be…

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  • Wed, 02 Nov 2016 09:09:28 +0000: Setup Reduction SMED Coaching - Lean Manufacturing Tools

    “Send me a video and I will help reduce your setup times” Reducing setup time is a vital part of most Lean implementations if you want to be able to reduce batch sizes and improve process efficiency. SMED as the…

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  • Wed, 02 Nov 2016 09:08:11 +0000: Lean Process Improvement Coaching - Lean Manufacturing Tools

    “Send me a video of your process and I will help make it more efficient” One of the most common areas that companies are looking for when looking for any form of lean support is to improve their process efficiency.…

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  • Sun, 31 May 2015 08:57:44 +0000: 5S Training Presentations - Lean Manufacturing Tools

    5S PPTx and 5S PDF Downloads If you want to learn all about 5S then the following 5S presentations in ppt (PowerPoint) format and PDF format are available to you for free download. Please note that these 5S Training presentation…

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