Lean Basic for Training

5/27/2018 Lean Basic for Training

1/98 2006 Hitachi Global Storage Technologies Hitachi Confidential



1885

1913

, , , .)

1955-1990

1993-



!!

...More details to come

Define Value

Value Stream Map /

Pull Production

Continuous Flow

Strive for Perfection)



8

Overproduction

Transportation

Inventory

Waiting

Processing

Rework

Motion

Intellect



:

/

:

: /

/



:

:

:



:



:

:



Cola

:/

:

:

/



/ :

/



/

:

:



:

First Time


14/98

2006 Hitachi Global Storage Technologies Hitachi Confidential

:

/

(

:

/


15/98


:/


16/98


:

/

:

/


17/98


ValuePrice


18/98


+=

=


19/98


?

3 forms a minute

1 batch per minute

6 0 s ec Tak t

1 Batch 1 Batch 1 Batch 1 Batch 1 Batch 15 Batches 1 Batch 1 Batch 1 Batch 1 Batch 1 Batch 1 Batch

40 Forms 60 Sec 30 Sec 30 sec 100 Sec 20 Sec 20 Sec

Walk Walk Walk Walk walk walk

VA 60 30 30 100 20 20 20 280 VA

NVA 800 60 15 60 30 15 30 30 15 900 100 15 20 20 30 15 20 20 2195 NVA

40/3

Time is approximate. VAR 0.113131

11%

AS IS VSM speedy Corporation By Jerry Coover Date 12-14-04

Customer

Supplier

if used

WS 1

numbers

1 to 10individual

blank

forms

Batch

Work station 2

A to F

Batch

Work station 2

A to F

Batch

Work station 2A

G to Z

Batch

Work station

3

Red / Blue

slash

Batch

Work station

4

QA.WalkWalkWalkWalkWalk

Verbal

Make as many

as possible

Batch

Finished

Goods

FinishedGoods

Walk


20/98


I50 pcs.

3

C/T= Oper. 12 secsMach. 30 secs

C/O = 15 mins.

Uptime= 75 %

3Reject rate= 13%

2-X/wk.

Push Arrow

F I F O


21/98


Daily Schedule

Withdrawal Kanban Production KanbanSignal Kanban

OXOXLevel Loading

Heijunka BoxKanban Mailbox


22/98


(CT)

CT

(VCT)

VCT

(LT) Lead Time.

LT

: VCT < CT < LT


23/98


2X/day

CustomerSuppliers

Cook Dogs Put in Bun Wrap/Freeze

C/O = 5 mins.

Uptime = 85 %

Scrap Rate = 13%

1 Operators

C/O = 0 mins.

Uptime = 100%

Scrap Rate = 9%

1 Operators

C/O = 3 mins.

Uptime = 90 %

Scrap Rate = 5%

1 Operators

I

130 dogs

I

60 dogs

I

150 dogs

I

515 dogs

Material Control

Make

Hot Dogs

I300 buns

Cut Buns

C/T=Oper. 11 secs

C/O = 0 mins.

Uptime = 100 %

Scrap Rate = 9%

1 Operators

I

345 buns

Order

Forecast

Order

Materials

Daily

Order

960 Hotdogs/day

2 shifts

Shipping

Staging

600 buns and dogs

per load

TAKT Time = 60 Seconds

Leadtimes

(TT x #pcs)

300 mins.345 mins.

Value-added

times

Value Added Time128 sec

150 mins.130 mins. 60 mins.515 mins.

515 mins 130 mins 60 mins 150 mins

Prod Lead Time

855 min = 51300 sec

C/T=Oper. 12 secs

Mach. 42 secs.

54 secs

54 sec

C/T=Oper. 17 secs

17 secs

17 sec

C/T=Oper. 22 secs

Mach.:35 secs

57 secs

57 sec


24/98


5S

5S

5S

5S

5S.

5S


25/98


5S

5Ss:

Step 5:

Step 4:

Step 3:

Step 2:

Step 1:

SustainingShitsuke

StandardizeSeketsu

ShiningSeiso

StorageSeiton

Sorting

Seiri

5 S is not a Japanese I dea. I t is good common sense!


26/98


(Sorting)

Sorting

Red Tag


27/98


Storage

/


28/98


Shining


29/98


Standardizing

---

5S

30!


30/98


Sustaining

Checklist


31/98


5S

5S

5S

5S

5S:


32/98


:


33/98


(cont.)

1 2 3 4 5 6

7 8 9 10 11 12

VisualAudio


34/98


.


35/98


(Poka-yoke)?

Poka-Yoke(poka)(yokeru).

Poka-YokeShigeo Shingo.

Poka-YokeShigeo Shingo

.

: ---.

:


36/98


?

100%

100%100%


37/98


Park


38/98


New Worker

Forgetfulness

Willful Errors

/

Lack of Standard

Surprise Errors--Equipment

??


39/98


/

.

Defects


40/98


.

Takt Time.

.

Takt.

.

?


41/98


Volume ()Time ()

=

=


42/98


Cycle Time:

Takt Time:

.

Vs


43/98


Takt time

Op1 Op3 Op4 Op5 Op6

Op2

Vs


44/98


.

/


45/98


/

Standard Operations

ACME

Standard Operations


46/98


Standard Operations

1..2..3.

.


47/98


:

.

!


48/98


!

2

1

3

4

6

7

8

5


49/98


.

.


50/98


Kanban Square

Signal Kanban

Material Kanban


51/98


X X X

XX

X

Signal Kanban


52/98


Signal Kanban

.

( .)


53/98


(.)

407

408

409

407 408 409

( .)


54/98


(.)

407 408 409

407

408

409

( .)


55/98


(.)

407 408 409

407

408

409

(.)


56/98


( )

407 408 409

!409!

407

408

409

(.)


57/98


( )

407 408 409

407

408

409

(.)


58/98


( )

407 408 409

407

408

409

(.)


59/98


( )

407 408 409

407

408

409

(.)


60/98


( )

407 408 409

407

408

409


61/98


Production Kanbans

Withdrawal Kanbans

Supplier Kanbans


62/98


A

B


63/98



64/98


FIXED ORDER CYCLEKANBAN ORDER SUPPLIER TIME RETURN TOCOLLECTION LOTSIZING FAX TO DOCK POINT OF USE

(If Required)

NOTE: UNIQUE PURCHASED PART (SP)

CONSTANT ORDER CYCLE

(COMMON CARRIER)STAGING POINT:

DEPT 13

ORDER CYCLE

WEEKLY

SUPPLY POINT: MATL.

PLANNERS

BOX/RECEIVING

PRESSED METALS

REF.DRAWNINGNO.

CONTAINER TYPE:

BOX

KANBAN QUANTITY

1500

PART NAME

BUSHING

SUPPLIER KANBAN

PART #

KANBAN #

____ OF ___


65/98


.

.

.

.

.

.

.

.

TPMTotal Productive Maintenance


66/98


Total Productive Maintenance

?

TPM .

TPM


67/98


Equipment Operator

Maintenance Personnel


68/98


Reactive

.

Preventative

.

Predictive

.Product

or

Process

Fa il u re Mode Fa il u re E ffec ts

S

E

V

Causes

O

C

C

Controls

D

E

T

R

P

N

Actions Plans PS

PO

PD

p

rp

n

Reactive


69/98


Preventative Maintenance


70/98

2006 Hitachi Global Storage Technologies Hitachi ConfidentialGood use of a FMEA

:

100

Preventative Maintenance


71/98


Product or

Process

Failure Mode

Failure

Effects

SEV

Causes

OCC

Controls

DET RPN

Actions Plans

PS PO PD Prpn


72/98


Preventative Maintenance Diagnostics

Thermistor

Thermometer

,,

Infrared

Accelerometer Stethoscope

Stroboscope

Laser alignment


73/98


X-

/

Ph

Preventative Maintenance Diagnostics

Predictive Maintenance


74/98


Six Big Losses


75/98


1. Breakdown losses

2.Set-up and Adjustment losses

3.Minor stoppage losses

10

4.Speed losses

5.Quality defects and rework losses

6.Yield losses /)

TPM


76/98


.

!

!!!

TPM:


77/98


TPM23.


78/98


:!


79/98


?


80/98


?


81/98


?

?


82/98



83/98



84/98


1

2

3

45

---


85/98


vs.

: .: .

1


86/98


Total setup time

internal external

1

2

3


87/98


/

---


88/98


:.

2

---


89/98


3

?


90/98


,,


91/98


%

?

---


92/98


o

o

o Fixed Stops

oo

4


93/98


No Dial

Indicators

?


94/98


Fastening


95/98


!

10

!

.

!

---


96/98


:

5


97/98


S.P.C.


98/98

Die or Fixture MovementTightening or LooseningAutomatic AdjustmentsPallet SystemsTool Changers

Lean Basic for Training

Documents

Transcript of Lean Basic for Training