C O N S U L T A N T S E N G I N E E R S S T R A T E G I S T S www.strategosinc.com Essentials Lean Manufacturing Defined & Explained

These are core disciplines. Not every organization requires them all. Others require supplementary disciplines such as . Determining which disciplines are most important and/or urgent is the subject of Strategos' "Workshop for Wagon masters" that formulates an implementation plan. Lean Manufacturing is "manufacturing without waste." Waste has many forms. Inventory Material, time, idle equipment, and Besides core disciplines, there inventory are examples. Most companies is an overall theme of waste 70%-90% of their available inventory reduction. Inventory resources. Even the best Lean hides waste. Almost every Manufacturers probably waste 30%. imperfection or problem creates a need for inventory. Hence, This is an enormous opportunity. Lean inventory is a result and Manufacturing and measures the imperfection of the system. improve material handling, inventory, Inventory also devours capital. For most quality, scheduling, personnel and customer companies, the inventory savings alone satisfaction. These improvements are not provide funding for implementing the just a few percentage points, they are order- system and the largest savings occur early of-magnitude. Typically such improvements on. Thus, Lean Manufacturing is essentially range from 30%-90%. The benefits have self-funding. been documented by academic researchers and some of their work is available at our website. People & Technology Factories include people. To The Core Disciplines function well, people and technology must integrate in a Most waste is invisible. Nor is elimination system that exploits the strengths easy. A set of techniques that identify and and minimizing the limitations of each eliminate waste has evolved: "Lean component. Every core discipline has a Manufacturing." psychological component. Eric Trist called this a Socio-Technical System. You can · Cellular Manufacturing learn more about Socio-Technical systems · Pull Scheduling () on our site including a compilation of the · Six Sigma/Total Quality primary principles. · Rapid Setup · Team Development

Page 1 Strategos, Inc.- 3916 Wyandotte - Kansas City Missouri 64111 – 816.931.1414 C O N S U L T A N T S E N G I N E E R S S T R A T E G I S T S www.strategosinc.com starting with market requirements and The Systems Perspective focusing on a consistent, doable set of Key The core disciplines are Manufacturing Tasks. These are the tasks interdependent. Each acts that win orders in the marketplace. upon and improves the others in a continuous In strategy, science meets its limits. Here, art "Virtuous Circle". Over time, this and intuition tend to dominate although reinforcement builds momentum like a there are some basic principles and snowball rolling downhill. Results for the analytical tools. system are greater than the separate effects. For more, see "Manufacturing As A Using The Strategos Website System." We hope to provide useful information and tools in addition to showing you how Science Vs. Slogans Strategos can assist. Our site has several At Strategos, we prefer a scientific and hundred pages devoted to various aspects of engineering perspective rather than slogans, Manufacturing Strategy and Lean edicts, imitation and proselytizing. Manufacturing. They include:

Science necessarily includes the human · Articles disciplines since humans are part of the · Case Studies system. The work of Maslow, MacGregor, · Tools & Downloads Trist and many others who studied human · Links To Resources psychology in the workplace is part of our repertoire. The Site Guide that follows illustrates the scope and depth of this information and the This fundamental approach allows us to unique insights that we bring. carry principles into new and different industries where there are no examples to This is not just another Lean copy. Lean principles are at work today in Manufacturing site. It is a place to come verything from insurance to funeral services back to again and again. and we have helped with some of this transfer. A Personal Note Manufacturing Strategy I hope you find our site Wickham Skinner points out that a blind interesting, informative and imitation of 30-year-old, widely known, thought provoking. We intend Japanese techniques is unlikely to assure to challenge your thoughts— competitive advantage. Even if direct that is one way we learn. We also invite you imitation worked (and it does not), to challenge our thoughts. companies who attempt this will always be Quarterman Lee years behind the leaders.

The Manufacturing Strategy approach can build sustained competitive advantage by

Page 2 Strategos, Inc.- 3916 Wyandotte - Kansas City Missouri 64111 – 816.931.1414 C O N S U L T A N T S E N G I N E E R S S T R A T E G I S T S www.strategosinc.com Strategos Website Guide

Topic Training Info - Tools - Downloads Other Developing Your Training Plan Article- Leadership Lessons from "Twelve Useful Links General O'Clock High" Book Reviews The Meaning of Kaizen Lean Briefing- Lean Manufacturing Defined & Explained Newsletter Lean Manufacturing Download Central How To Design Workcells- Seminar Lean Manufacturing Case Study "Life In A Workcell"-Video Workcells- The Heart of Lean Manufacturing Cellular How To Design Workcells Manufacturing Workcell Design (Book Chapter) Is A Kaizen Blitz Right For You? & Group One Piece Flow Technology Group Technology Just In Time, Toyota & Lean Manufacturing Balancing The Work In Workcells All About Takt Time Kanban & Lean Scheduling Strategies Kanban Game (Software) Kanban Scheduling- Designing A Kanban Scheduling Designing Kanban Scheduling System Simple, Effective, Scheduling System Rational Lot Sizing Demanding (Case Inventory Record Accuracy Study) Layout & Facility Design for Lean Mfg. Plant Layout & Facilities Planning Facility Book-Facilities & Workplace Design Facility Planning Template & Forms Planning A Production Miracle at Willow Run

Experience of Lean Manufacturing A Systems View of Lean Manufacturing Lean Briefing- Lean Is A Kaizen Blitz Right For You? Newsletter Manufacturing The Myth of One Piece Flow Video- World Business Benefits of Lean Manufacturing Review Socio-Technical Systems Workshop for Wagon masters- Lean Assessment (Template) Lean Success- (Case Manufacturing Planning, Leading, Managing Lean The Fuss About Inventory Study) Strategy Manufacturing Factory Science (Article) Lean Assessment (Mini-Workshop) Great Nuclear Fizzle (Case Study) Accounting, Finance & Metrics The Focused Factory Maintenance for Lean Manufacturing High Reliability Maintenance Maintenance

Setup Rapid Setup for Lean Manufacturing Setup Reduction- The Missing Piece Reduction

Strategos Training Information About Strategos & The Who Should Attend? Team

Team Building Peak Performance Teams Virtuous Circle of Team Motivation Leadership for Lean Manufacturing The Power of Teams & Human Issues Creating & Sustaining A Lean Tales From Twelve O’clock High Culture Decoding The DNA of Toyota Total Quality & Common Sense Six Sigma Quick & Easy Kaizen Root Cause Analysis ISO 9000 - What Is It? Six Sigma Quick & Easy Kaizen Seminar ISO 9000 Checklist Managerial Problem Solving The Cost of Quality Warehousing How To Design A World Class Warehouse

Page 3 Strategos, Inc.- 3916 Wyandotte - Kansas City Missouri 64111 – 816.931.1414