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The document outlines a workshop roadmap for Cal Poly University's Lean Systems 101 workshop. The workshop introduces lean concepts like defining value, eliminating waste, quality at the source, and 5S. It covers topics such as the goal of lean being value, types of waste, basic lean elements, benefits of lean production, and 5S and visual management. The workshop concludes with additional resources and a question and answer session.
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- 2. cait@dozuki.com | @CaitEmmaSmith Director of Outreach Dozuki Cait Emma Smith
- 3. Karen Bangs Faculty Member California Polytechnic State University krbangs@calpoly.edu | 805-756-6210
- 4. Cal Poly Universitys Lean Systems 101
- 5. Workshop Roadmap Cal Poly Universitys Lean Systems 101 De鍖ning The Goal The House of Lean Tools Types of waste Cal Polys Basic Elements Quality at the Source Bene鍖ts of Lean Production 5S and Visual Management Additional Resources Audience Q&A
- 6. Cal Poly Universitys Lean Systems 101 THE GOAL: VALUE Respect for People Continuous Improvement FOUNDATION: MANAGEMENT SUPPORT Product Development Flow
- 7. Cal Poly Universitys Lean Systems 101 But how can you experience continuous improvement? Eliminating waste.
- 8. Cal Poly Universitys Lean Systems 101 CUSTOMER SATISFACTION BUSINESS SUCCESS RESPECT FOR PEOPLE Team Building Empowerment Cross Training Hoshin Supplier Relationships JIT Pull Flow TAKT Time Heijunka Cell Design SMED JIDOKA Poka-yoke And on Autonomation 5 Ways Line Stops Built in Quality STABILITY & STANDARDIZATION
- 9. Cal Poly Universitys Lean Systems 101 1. Finished Goods 2. Waiting 3. Transporting 4. Over Processing Types of Waste 5. Factory Inventory 6. Movement 7. Defects 8. Talent
- 10. Cal Poly Universitys Lean Systems 101 Types of Waste: 1. Finished Goods, 2. Waiting, 3. Transporting
- 11. Cal Poly Universitys Lean Systems 101 Types of Waste: 4. Over Processing, 5. Factory Inventory
- 12. Cal Poly Universitys Lean Systems 101 Types of Waste: 6. Motion, 7. Defects, and 8. Talent
- 13. Cal Poly Universitys Lean Systems 101 Basic Elements 1. Flexible resources* 2. Celluar layouts* 3. Pull production system 4. Kanban production 5. Small lot production 6.Quick setups 7. Uniform production levels 8. Quality at the source* 9. Total productive maintenance 10. Supplier networks
- 14. Cal Poly Universitys Lean Systems 101 Flexible Resources and Cellular Layouts Multifunctional resources Manufacturing cells
- 15. Cal Poly Universitys Lean Systems 101 Multifunctional resources: cross trained workers, general purpose machines and equipment, and common raw materials Resources Webinars In-houseE-courses
- 16. Cal Poly Universitys Lean Systems 101 Manufacturing cells: product layout and TAKT Time BEFORE AFTER A B C A B C
- 17. Cal Poly Universitys Lean Systems 101 Quality at the Source | Visual Control
- 18. Quality at the Source | Poka-Yokes Cal Poly Universitys Lean Systems 101
- 19. Cal Poly Universitys Lean Systems 101 Basic Elements In Review 1. Flexible resources 2. Celluar layouts 3. Pull production system 4. Kanban production 5. Small lot production 6.Quick setups 7. Uniform production levels 8. Quality at the source 9. Total productive maintenance 10. Supplier networks
- 20. Benefits of Lean Production Cal Poly Universitys Lean Systems 101 Reduced inventory Improved quality Lower costs Reduced space requirements Shorter lead time Increased productivity Greater 鍖exibility Better relationships with suppliers Simpli鍖ed scheduling and control activities Increased capacity Better use of human resources More product variety
- 21. 5S and Visual Management Cal Poly Universitys Lean Systems 101
- 22. Cal Poly Universitys Lean Systems 101 5S Scan: Seiri (sort) Goal: Keep only what you need Eliminate or correct: Unneeded equipment, tools, furniture; unneeded items on walls, bulletins; items blocking aisles or stacked in corners; unneeded inventory, supplies, parts; safety hazards
- 23. Cal Poly Universitys Lean Systems 101 5S Scan: Seiton (set in order) Goal: A place for everything and everything in its place Eliminate or correct: Items not in their correct places; correct places not obvious; aisles, workstations, and equipment locations not indicated items not put away immediately after use
- 24. Cal Poly Universitys Lean Systems 101 5S Scan: Seisou (shine) Goal: Cleaning and looking for ways to keep clean and organized. Eliminate or correct: Floors, walls, stairs, equipment, and surfaces; cleaning materials not easily accessible, labels, signs broken or unclean; other cleaning problems
- 25. Cal Poly Universitys Lean Systems 101 5S Scan: Seiketsu (standardize) Goal: Maintaining and monitoring the first three categories Eliminate or correct: Necessary information not visible; standards not known; checklists missing; quantities and limits not easily recognizable; items cant be located within 30 seconds
- 26. Cal Poly Universitys Lean Systems 101 5S Scan: Shisuke (sustain) Goal: Sticking to the rules Eliminate or correct: Number of workers without 5S training; number of daily 5S inspections not performed; number of personal items not stored; number of times job aids not available or up-to-date
- 27. Cal Poly Universitys Lean Systems 101 Additional Resources Gemba Academy Google Institute of Industrial Engineers Central Coast Lean The Toyota Way by Je鍖rey Liker
- 28. Cal Poly Universitys Lean Systems 101 Audience Q&A
- 29. LinkedIn: Dozuki Twitter: @Dozuki Forum: dozuki.com/Answers/Ask/Lean_Systems Cal Poly Universitys Lean Systems 101 Continue the Conversation
- 30. Cal Poly Universitys Lean Systems 101 cait@dozuki.com @CaitEmmaSmith Director of Outreach Dozuki Cait Emma Smith krbangs@calpoly.edu 805-756-6210 Faculty Member California Polytechnic State University Karen Bangs Thanks for joining us today!