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Introduction
Key Lean Principles
Cornerstones of an Effective Lean Program
Performance Metrics
What are Adaptive’s Visual Workplace Solutions?
"after a decade downsizing and reengineering most manufacturing
companies are still searching for the formula to sustain business
growth…"
The purpose of this brief overview is to share key principles
and examples to guide your actions in becoming a lean manufacturer
with a laser like focus!
Introduction
It
is unlikely that tomorrow’s customer will become less demanding.
Therefore, today’s business must focus on satisfying the customer
in an even more competitive marketplace. Satisfying the customer
while making a profit requires extraordinary acts of flexibility,
impeccable quality and incredible asset efficiency. Companies
committed to becoming lean are finding incredible success in their
ability to satisfy the customer and increase market share.
What
if your business could achieve…
- 40%
- 50% Reduction in cycle time
- 25%
- 35% Reduction in set up time
- 35%
- 45% Reduction in down time
- 30%
- 40% Improvement in productivity
- 25%
- 35% Reduction in WIP
- 35%
- 45% Reduction in scrap
- 40%
- 80% Reduction in travel distance
- 20%
- 30% Reduction in floor space
Companies
fully engaged in lean manufacturing programs have achieved results
like these.
Key
Lean Principles
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1.
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Define
value precisely from the end customer perspective. |
- specific
product needs.
- specific
capabilities.
- specific
price, delivery and quality expectations.
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2.
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Identify
the entire value stream for each product line and eliminate
waste. |
- Product
definition and development.
- Material
transformation.
- Information
management.
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3.
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Make
the value added activities flow. |
- Through
radical shifts in process methodology and organizational
structure.
- Improving
processes from end-to-end by eliminating scrap, downtime
and WIP.
- Moving
towards continuous operations vs. batch processing.
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4.
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Provide
what the customer wants only when the customer wants it. |
- Let
the end customer pull products from the manufacturing
value stream.
- Minimize
finished goods inventories and WIP.
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5.
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Pursue
perfection through continuous improvement. When lean principles
are applied throughout the value stream, odd things begin to
happen: |
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People recognize there is no end to reducing effort, time,
space and mistakes.
- Your
products become more closely aligned with the customer
needs.
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Cornerstones of
an Effective Lean Program
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Create
an Exciting Culture
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at every level of the organization. |
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Empower
a Participative Environment
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-
including those closest to the work. |
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Provide
Meaningful Visual Measurements
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-
metrics that align with business objectives. |
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Organize
a Visual and Orderly Workplace
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-
"a place for everything and everything in its place". |
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Encourage
a Continuous Learning Environment
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-
managing for daily improvement |
Performance
Metrics
Useful,
accurate, current and visible measurements are the scores required
to empower your lean teams to continuously improve your company’s
performance.
Discover
the dynamics of measurements:
- The
measurement system is the bedrock of any change process.
- Measures
will be constantly changing.
- Move
towards driving metrics vs. lagging reports.
- Information
requirements increase as you get closer to lean.
- Speed
of information will grow faster than productivity gains.
Characteristics
of useful manufacturing measurements:
- Reflects
customer requirements.
- Coordinates
with other goals.
- Quantifies
success.
- Targets
waste elimination.
- Drives
proactive improvement.
- Extremely
visible.
What
are Adaptive’s Visual Workplace Solutions?
"If
you can’t see your data, does it really exist?"
Think
about it. How much have you spent on information systems and equipment
that create great reports that are reviewed after the fact? What
if key elements of these reports were available to the people
that really need them, instantly?
Introduction
In
order to support the key principles of Lean Manufacturing programs
Adaptive has produced a family of Visual Workplace Solutions designed
specifically to deliver key lean performance metrics to the people
that need them the most. Adaptive LED message displays are your
performance scoreboards to achieve impressive gains in a lean
environment.
What’s
the Score?
Selecting
what information you need displayed is critical to an effective
Lean Manufacturing program. As time goes on and your processes
improve you’ll find that your lean teams need different data to
take their next steps.
Lean
Performance Scores and Metrics
Putting
the right data in front of the right people will yield instant
results and improve morale at the same time.
People
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Output per labor hour
- Direct
labor per unit
- Indirect
labor per unit
- Units
per hour or hours per unit
- Overhead
cost per unit
Process
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Setup time
- On
time delivery
- Value
added ratio
- Reject
rate
- Rework
cost
- First
pass quality
- Cycle
time
- Material
Scrap
Get
Started Today!
Provide
your workforce with the scores they need to reach the next level.
It
can be as easy as hooking any Alpha LED display onto your
Ethernet network and updating the display from anywhere by making
entries into an Excel™ spreadsheet. Of course, you can use any
of your other Windows™ tools to create real time live data feeds
to displays all over your facility. Yes, it’s really that
simple!!!
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