LEAN Production – Easy and Comprehensive: A practical guide to lean processes explained with pictures

✍ Scribed by Roman Hänggi, André Fimpel, Roland Siegenthaler

• Publisher: Springer Vieweg
• Year: 2022
• Tongue: English
• Leaves: 213
• Category: Library

✦ Synopsis

No production is perfect. Waste always creeps into the processes, makes them slow, sluggish and expensive. Parts and material pile up in the warehouse, production takes place in unnecessarily large batches, transport is taking time, employees wait unproductively for their next task or products ship too late. The result is high production costs and disappointed customers.

The Lean movement has set itself the goal of uncovering waste, question it and eliminate it.

This book will explain in a simple and comprehensive way the Lean principles as well as the practical tools to make production processes as lean and value-added as possible. Because we all love stories, each method is entertainingly wrapped in an illustrated story. In this book, a barista who has to run marathon distances every day, the cup Tim struggles with overproduction and the LeanClean Inc. counts on your support to trim the vacuum cleaner production to maximum value creation with value stream mapping, spaghetti diagram, 5S or Kanban. For each topic, you will find our practical tips. They are the lessons learned from our Lean projects over the past 20 years in many countries. They will help you to implement your Lean initiatives even more effectively and successfully.

 

 

✦ Table of Contents

Foreword
Introduction
Contents
About the Authors
Abbreviations
1 The 7 Types of Waste
1.1 Why Do We Distinguish Waste?
1.2 Waste 1: Overproduction
Too Much and Too Soon
It Is Still Waste
1.3 Waste 2: Stock
Stock Gives a Sense of Security
The Money Is Not Only Fixed in the Goods!
Big Trucks and Changeable Weather
1.4 Waste 3: Transport
Parts Tourism
Whether a Few Meters or Halfway Around the World, Both Are Transport
1.5 Waste 4: Motion
Even Short Distances Lead to Espresso
Many Few Also Make a Lot
1.6 Waste 5: Waiting
If It Takes a Little Longer…
1.7 Waste 6: Unnecessary Processes
Newsletter and Lost Glasses
1.8 Waste 7: Scrap and Rework
Does Not Always Succeed the First Time
1.9 See and Understand Waste
Yes, But…
… Sometimes You Have to Look Closely …
1.10 Now It Is Your Turn
2 The 9 Principles for Eliminating Waste
2.1 With 9 Principles to Ideal Production
Why These 9 Principles in Particular?
2.2 Principle 1: Pull Principle
Bake, When the Customer Buys
2.3 Principle 2: Flow Principle
Your Name in Your Color
2.4 Principle 3: Takt Principle
Burger & Co
Distribute Content Equally
2.5 Principle 4: 0-Defect Principle
Break the Defect Chain
A Sustainable Error Culture
0-Defect Is Also a Question of Technology
The Four Stages of Intervention
0-Defect Culture
2.6 Principle 5: Separation of Waste and Value Creation
In the Operating Room, the “Surgeon–Nurse” Principle Applies
2.7 Principle 6: FIFO Principle
First Come, First Served
2.8 Principle 7: Minimum Distance
Many Roads Lead to Waste
2.9 Principle 8: Value Stream Orientation
Everything Has Its Value
2.10 Principle 9: Standardization
The Lean Anchor
2.11 Now It Is Your Turn
3 Lean Methods to See the Waste
3.1 Caution: Methods!
3.2 Welcome to LeanClean Inc.
LeanClean Inc. Needs You
The Three Products of LeanClean Inc.
A Factory Tour
The Competition Does Not Sleep
The Innards of the Elephant
3.3 First Analyze, Then Act
3.4 Method 1: Process Map
The Process Map of the Elephant Product Line
Discussion About Waste, Based on the Process Map
Interesting Facts About the Process Map
3.5 Method 2: Value Stream Analysis
The Value Stream of the Handle of the Elephant
The Customer and the Supplier
The Flow of Information
The Material Flow
The Timeline
Waste Flashes
And Now It Is Your Turn …
3.6 Method 3: OEE
A Matter of Time Regarding the Plastmaster 2000
Caution When Comparing OEEs
From Automatic OEE to the Smart Factory
3.7 Method 4: Handling Step Analysis
MuDa In The Engine
What Are Handling Steps?
3.8 Method 5: Operator Balance Chart
Work Distribution in the Elephant Assembly
3.9 Method 6: Spaghetti Diagram
A Long Way to the Mounted Handle
3.10 Method 7: Pareto Chart
From a Gut Feeling to Facts in Two Shifts
3.11 Method 8: Inventory Analysis
360-Degree View of LeanClean Inventories
4 Methods for Implementing the 9 Principles
4.1 Only the Implementation Brings the Benefit
4.2 Method 9: 5S
Let us Tackle It Together
The 1st S: Sorting (out)
The 2nd S: Shine
The 3rd S: Set in Order
The 4th S: Standardize
The 5th S: Securing the Standard
4.3 Method 10: Zoning
Subdividing the Workplace
Zoning Not only Works in Assembly
4.4 Method 11: SMED
The Plastmaster 2000 Is Aiming for the Pole Position
Recording the Setup Steps of the Plastmaster 2000
Analyze and Organize
Classify and Optimize Setup Steps
Implement Optimization Measures
Summary of the SMED Method
4.5 Method 12: Lean Shelf
Lean Shelf Creates Order
Are Shelves a Method?
4.6 Method 13: The Milk Run = Takted Route Trains
The First Route at LeanClean Inc.
Exchange empty milk bottle for a full…
The Milkrun Conquers Supplier Logistics
4.7 Method 14: Kanban
From “Push” to “Pull”
The Plan
Welcome to Reality
Replenishment for the Handles
Two? Three? Or Ten Containers?
Full Shelves – Like in the Supermarket
The Three Types of Kanban
The Kanban Signal
When Does Kanban Make Sense?
C-Parts Management
4.8 Method 15: Line Balancing
Balancing the Elephant Final Assembly
4.9 Method 16: Set Building
The Octopus Set
4.10 Method 17: Sequencing
A Chain of lucky Orders
Just-In-Sequence (JIS)
Do Not Step Out of Line!
When Is Sequencing the Right Choice?
4.11 Method 18: A3
The Soft Component Case
Solve Problems Systematically
Warrant for the Soft Component on the Handle
4.12 Method 19: Poka-yoke
The Incorrectly Mounted Motor
Poka-Yoke for the Motor Plug
Poka-Yoke for a Carefree Life
4.13 Method 20: Andon
Detect and Fix Faults in Real Time!
The Problem is Displayed – And Then?
4.14 Method 21: KPIs
Concrete KPIs for Each Production
Importance of KPIs in Lean Management
4.15 Method 22: Shopfloor Management
The Control of Lean Production
5 Lean Change
5.1 Change Never Ends
5.2 The Change Control Loop
5.3 Step 1: Wanting the Change
A Question of Attitude
... First the Management Must Want!
Create Your Personal Crisis with Facts, Figures and Data
5.4 Step 2: Build Knowledge
Train Every Employee
Preserving the Knowledge in Standards
5.5 Step 3: Develop a Vision
How Sharp Is the Image?
The Vision Does Not End at the Factory Gate
How Digital Is the Vision of the Future?
5.6 Step 4: Plan Implementation
Planning Is Teamwork
Workshops and Projects, but Also Quick Wins
Plan From the Inside Out and Upstream
Plan and Build Resources
5.7 Step 5: Implement Change
A Gap Between Knowing and Doing
The Lean Workshop Maker Space
Control the Implementation
5.8 And What Happens Next?
References