| Lean Manufacturing |
I Foreword
Lean Enterprise Defined
How It All Began
II. The Need for Change
Why Change?
Benefits of Lean
The Evolution to Lean
Touring a Traditional Operation
Lean v. Traditional Manufacturing
Batch and Queue
The Role of Management
Organization Changes
Resistance
The Role of Education
III. Lean Theory
Overview
Waste
The Types of Waste
Provide Value
Radical Change
Continuous Incremental Improvement
Lean Elements
Lean Rules
Lean Tools Overview
IV. Kaizen
Kaizen Defined
Philosophy
10 Principals
Problem Selection
Guidelines
Value-Added, Non Value-Added, Non-Value-Added
Required
Manufacturing Kaizen
Administrative Kaizen
V. Value Stream Mapping
VSM Defined
Purpose of VSM
Technology Used
The Current State Map
The Future State Map
Strategy
Getting Started
The Team
Developing a VSM
VSM Approach
Definitions and Icons
VI. Transforming the Enterprise
VII. SMED (Single Minute Exchange of Dies/Quick
Change
Audi
Goals
Traditional Concepts
Inventory
Benefits
Rules
Internal v. External Activities
Methodology
Observe and Document Current Process
Separate Internals from Externals
Develop Plan
Observe and Document New Process
Standardize New Process
Celebrate
VIII. TPM (Total Productive Maintenance
Introduction
Definition
Alternatives
Prevention Principles
Obstacles
Types of Breakdowns
Deterioration
How TPM is Implemented
Overall Equipment Effectiveness (OEE)
Calculating OEE
The Six Big Losses
Types of Maintenance
TPM Tools
Autonomous Maintenance
7 Steps to Autonomous Maintenance
Skills Training
TPM Strategy
IX. 5S
Introduction
Definition
Separate
Sort
Sweep
Standardize
Sustain
Safety
X. DFMA (Design for Manufacture and
Assembly
Definition
Traditional Approach
Concurrent Engineering
DFMA Principles
DFMA Rules
Why DFMA?
Design Techniques
Design Process
Design for Six Sigma Overview
DFMA Benefits
Product Release
XI. Kanban
Introduction
Definition
Pull v. Push Systems
Function
Applications
Information Flow
Types
Calculations
Information Requirements
Manufacturing Rules
Planner Rules
The Role of MRP
Electronic Systems
Inventory Carrying Costs
XII. Other Lean Tools
Standard Work
Visual Workplace Management
Error Proofing (Poka-Yoke)
Scheduling and Leveling (Heijunka)
Value Selling
XIII. Lean and Six Sigma Overview
XIV. Lean Accounting Overview
XV. Implementing Lean
Putting it All Together
Lean Road Map
Policy Development
Lean Implementation Plan
Lean Metrics
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