Lean Supply Chain Management II PDF

Lean Supply Chain Management II Dr. Melisa Özbiltekin Pala 1  REMINDER -To give information about topic which you select (Due Date: October 15, 2024 – 17:00 O’clock -send mail) -To make short presentation about your project topics (10 min. Pr...

Lean Supply Chain Management II Dr. Melisa Özbiltekin Pala 1  REMINDER -To give information about topic which you select (Due Date: October 15, 2024 – 17:00 O’clock -send mail) -To make short presentation about your project topics (10 min. Presentation, Just the information on why you chose that topic. Date: October, 22) -Interim report presentations (Date:12 November) + Interim Report (Date: 12 November – upload on moodle.) -Final Project Presentation (Date: 24 December & 31 December & 7 January) 2 REMEMBER FROM PREVIOUS WEEK ! House of lean 3 Lean Tools: KAIZEN Kaizen- “kai’ means “little” or “ongoing”. “Zen” means “for the better” or “good.” Small continuous improvements on everyone’s part leads to world class manufacturing. 4 Lean Tools: Poka yoke Mistake-proofing Poka-Yoke strategies eliminate human error from your processes so that defects never get to customers 5  Lean Tools: SMED Single Minute Exchange of Die (SMED) Aims to reduce set up times to single minutes To enable high frequency of changeovers Changeovers can vary in time from minutes to hours in manufacturing, but the idea is, through team-based continuous improvement, to keep reducing changeover time and cost so that things are produced in smaller batches or lot sizes. https://www.youtube.com/watch?v=UlIGI3laGAo 6  Lean Tools: Process chart Usually it is best to get a team together of employees who actually do the work along with coworkers from other areas, document the steps in the process (using digital photography), and come up with an agreed-upon best practice minimizing waste in the process. It can be useful to use a tool such as a process chart to identify opportunities in the work process by capturing data for each activity, such as time and distance. 7 EXAMPLE: VISUAL JOB AID (LOADING A TRUCK) 8  Lean Tools: Visual workplace The visual workplace is one of the fundamental concepts of Lean. When implementing visual systems it is important that they are easily found where needed, easy and quick to understand, and provide meaningful feedback. "to share vital information about the task at hand at-a-glance, without speaking a word." 9 Lean Tools: KANBAN Japanese word meaning: CARD or SIGN A Pull system Literally kan means Visual and ban is Card The kanban work system was originally developed over 60 years ago by manufacturing engineers at Toyota. K Kanban is a visual process and project management tool first developed in Japan by Toyota. 10 What Kanban Does Major elements of Kanban; What to pull When to pull it How much to pull Where to pull (from/to) 11  A typical kanban card provides: - Supply Information: Supplier Name & Stocking Location - Part Information: ID Number, quantity - Customer Information: Storage Location, Group Location, Kanban number 12  The Single-Card Kanban System Kanban card for Storage product 1 area Kanban card for Receiving post product 2 Empty containers Assembly line 1 O2 Fabrication cell O1 O3 Assembly line 2 Full containers O2 13  The Single-Card Kanban System Kanban card for Storage product 1 area Kanban card for Receiving post product 2 Empty containers Assembly line 1 O2 Fabrication cell O1 O3 Assembly line 2 Full containers O2 14  The Single-Card Kanban System Kanban card for Storage product 1 area Kanban card for Receiving post product 2 Empty containers Assembly line 1 O2 Fabrication cell O1 O3 Assembly line 2 Full containers O2 15  The Single-Card Kanban System Kanban card for Storage product 1 area Kanban card for Receiving post product 2 Empty containers Assembly line 1 O2 Fabrication cell O1 O3 Assembly line 2 Full containers O2 16  The Single-Card Kanban System Kanban card for Storage product 1 area Kanban card for Receiving post product 2 Empty containers Assembly line 1 O2 Fabrication cell O1 O3 Assembly line 2 Full containers O2 17  The Single-Card Kanban System Kanban card for Storage product 1 area Kanban card for Receiving post product 2 Empty containers Assembly line 1 O2 Fabrication cell O1 O3 Assembly line 2 Full containers O2 18  The Single-Card Kanban System Kanban card for Storage product 1 area Kanban card for Receiving post product 2 Empty containers Assembly line 1 O2 Fabrication cell O1 O3 Assembly line 2 Full containers O2 19  https://www.youtube.com/watch?app=desktop&v=Ex_mBAmroj4 Lean Tools: Standardized work Standardized work refers to the standardization of best work practices—as the work is actually done in real life. The idea is to make work safe and repeatable with as little variation as possible along with high productivity. It is the best combination of employees, equipment, materials, and procedures. Detailed work instructions are required if the work is to be completed consistently by different operators 20  Simple Calculations and Terms about Lean Times (Value Stream Mapping Metrics) Cycle Time: the average time taken to complete a single unit. Takt Time: Takt Time is a measure of the amount of time between the completion of one unit and the beginning of the next. (speeds up production) Lead Time: Lead time covers whole order fulfillment from order placement to delivering completed goods or services. Throughput Time: Throughput time is the time it takes for goods to go through the production process (operational) 21 22  Cycle time should be balanced to takt time. If cycle time exceeds takt time, the process can’t meet demand. If cycle time is shorter than takt time, the process is inefficient. 23 Example 1 24