Value Stream Mapping—An Introduction

Total Page:16

File Type:pdf, Size:1020Kb

Value Stream Mapping—An Introduction LEAN LESSONS Value Stream Mapping—an Introduction by Tony Manos alue stream mapping (VSM) process steps from order entry to easy ways to learn a language that can be an extremely powerful delivery. anyone in your organization can V tool, combining material pro- The value stream in VSM is the understand—a key element when cessing steps with information flow as point at which value is actually added communicating with process maps. well as other important related data. to the product or service by changing Building a VSM offers detail that goes VSM is arguably one of the most pow- beyond the amount of information erful lean tools for an organization you can relay with any standard flow- wanting to plan, implement and chart. improve on its lean journey. This tool A tool that combines allows users to create a solid imple- material processing Value Stream Scope mentation plan that will make the Understanding the scope of the most of their available resources. steps, information flow. value stream under examination is an For a lean journey, think of VSM as important place to start the VSM task. the launch pad to begin identifying Think of the scope as the door to door and improving a process family. VSM the market form or function to meet process for a facility level map. A is about sparking change—declutter- the customer’s needs. For example, departmental or interdepartmental ing the process of the nonessential value adding activities can be things practice is considered a process level activities that don’t add value but like: machining, assembly, welding, map. When multiple plants, cus- waste time and resources. drilling, folding, painting and so on. If tomers or suppliers are included, an VSM, as it is known today, stems you are not adding value, you are extended level map is created. from Toyota Motor Co.’s material and probably adding muda, (the Japanese Consider an extended level map as information flow diagrams.1, 2 In its word for waste). the view of the values stream at 60,000 most basic form, VSM shows the Pictorial representations of VSM are feet, the facility level map at 30,000 FIGURE 1 Process Family Matrix Example 1. Quoting 3. Credit review 4. Purchasing preparation 6. Tool 7. Scheduling 12. Cut to length 13. Slitting 17. Press break 18. Stamping Process family 2. Order entry 5. Order review 8. Receiving 9. Perforating 10. Leveling 11. Shearing 14. Radius rolling 15. Punching 16. Embosing 19. Outside service 21. Shipping 20. Packaging Name 150 80,000 lb/mo X X X X X X X X X X X 1 Coil to coil ORM005 80,000 lb/mo X X X X X X X X X X X 1 Coil to coil 020 AI GLD 5,000 pcs/mo X X X X X X X X X X X X X 2 Ornamental 020 AI Stuco 1,000 pcs/mo X X X X X X X X X X X X X 2 Ornamental 73518 400 pcs/mo X X X X X X X X X X X X X X X 3 Fab flat Ballast 300,000 lb/mo X X X X X X 4 Ballast Nordham 100 pcs/yr X X X X X X X 5 Pass through 611402401 250 pcs/mo X X X X X X X X X X X X X X X 6 Fab form VT4880 50 pcs/mo X X X X X X X X X X X X X X X 6 Fab form EAW435? 150 pcs/mo X X X X X X X X X X X X X X X X 6 Fab form YNG Filter 25 pcs/mo X X X X X X X X X X X X X X X 6 Fab form Gehl 001 150 pcs/mo X X X X X X X X X X X X X X X 6 Fab form 509566 700 pcs/mo X X X X X X X X X X X X 7 Coil to sheet to size 601 250 pcs/mo X X X X X X X X X X X X X 7 Coil to sheet to size 020 AI MF 8,000 pcs/mo X X X X X X X X X X X X 8 Coil to blank Nailor 500 pcs/mo X X X X X X X X X X X X X 8 Coil to blank 202262 20,000 pcs/mo X X X X X X X X X X X X X Stock Plate 250,000 lb/mo X X X X X X X X X X X X 9 Stock plate 64 I JUNE 2006 I www.asq.org FIGURE 2 Common VSM Icons Information flow Office Office Hardcopy Department/work center Electronic Software Warehouse Office/support data box Manufacturing/shop Supplier/Outside processing Material flow P/T = Processing time C/T = Cycle time Dist = Distance Movement Diff = Difficulty (1-5) M/T = Machine time Qty = Quantity C/O = Changeover C/O = Changeover FPY = First pass yield Push A&C = Accurate & Complete FPY = First pass yield OTD = On-time delivery Prior = Prioritize Rel. = Reliability Serv = Service level Customers/ Rel. = Reliability Qty = Quantity per ____ Expd = Expediting costs suppliers Qty = Quantity per ____ = Number of people/shift = Number of people/shift Truck - deliveries/ shipments Q Queue/waiting I Inventory Pe r son Production (make) Kanban Withdrawal Kaizen?burst/ Withdrawal (move) improvement Loop Go see Kanban Supermarket Supplier (batching) Kanban Maximum - FIFO - Kanbans?arriving in groups (First-in, first-out) Inventory or queue time VA Value added time Heijunka Cycle or (Level loading) process time NVA Nonvalue added time Kanban?route OXOX feet and the process level map at team and how it can affect decision Finally, never create a map with a 10,000 feet. making and action. A good team size team of one. You will not get enough It is best to start at diagramming a is usually between seven and 10 valuable input or cross functional dia- facility level map before attempting to members. This size makes it easier for logue or the results may be biased for draw a process level map or extended members to conduct interviews and one area, person or department. level map so you do not optimize one “walk the flow,” that is, actually visit- Kaizen Kick-Off area and suboptimize another. This ing each of the work areas affected by column will focus on the facility level the process evaluation and included Once the team is formed, a three map. in the VSM to see firsthand how day kaizen (Japanese for “change for things work or don’t work. the better”) event, as seen in Table 1, Ready a Team for the Event Predictably, the larger the team, the is usually enough time to create the The best—and probably easiest— more difficult it may be to manage. If current state and future state maps, way to create a VSM is to form a cross the team has fewer than seven mem- along with the draft plan (more detail functional team that includes supervi- bers, there may not be enough voices on these deliverables is highlighted sory or managerial level members to provide well-rounded input. later). More time may be needed to from throughout the organization. Representatives from departments like sales, customer service, schedul- TABLE 1 Typical Three-Day VSM Kaizen Event Agenda ing, purchasing, operations, inventory control, maintenance, quality and Day 1 Day 2 Day 3 information technology can be valu- • Introduce VSM. • Draw the current state • Create the future state able contributors to this part of the • Determine process map. map. VSM journey. Even customers or sup- families. • Perform lean concepts • Develop the draft plan. pliers—both internal or external—add •Walk the flow and training. unique perspectives. gather information. Be aware of the actual size of this QUALITY PROGRESS I JUNE 2006 I 65 LEAN LESSONS FIGURE 3 VSM Current State Map Example complete the detailed draft plan and the parts (for example, compo- included in the original matrix. After determine the resources required to nents, stock keeping units, fin- closer examination, the team that implement the lean ideas. It is impor- ished good items or services) your thought its company had only one tant to designate an individual with organization makes or provides. process family actually had nine fami- previous experience in VSM to facili- • Place an X in the corresponding lies. tate this kaizen event. box if the part goes through the After completing this vital step, At the kaizen event, the team must processing step. examine the matrix and look for parts complete four important steps to Many cross functional teams skip that go through similar or the exact progress through VSM: this step in the process. A team may same processing steps. Search for • Determine the process family. decide this step seems unnecessary. items or parts that share about 80% of • Draw the current state map. The team may mistakenly believe it the steps. Look for items or parts that • Determine and draw the future has already identified the value would make sense if they were created state map. streams, or it may consider this step alongside each other in a manufactur- • Draft a plan to arrive at the future too difficult or complicated to per- ing cell. In other words, consider items state. form. or parts that share many of the same I must emphasize this point again: steps and procedures that can be creat- Process Family Do not skip this step.
Recommended publications
  • CONTINUOUS IMPROVEMENT CONSULTING 2 First Choice Pocket Guide First Choice Pocket Guide 3
    DHL FIRST CHOICE CONTINUOUS IMPROVEMENT CONSULTING 2 First Choice Pocket Guide First Choice Pocket Guide 3 CONTENTS Introduction 4 Methodologies 6 ACT 8 DMAIC 10 Lean 12 Tools 14 5S Methodology 16 5 Why 18 DILO (Day In Life Of) 20 Effort-Benefit-Matrix 22 Spaghetti Diagram 24 More information 27 To simplify the understanding of each tool a standard structure has been used for all tool deep-dives: Goals/Benefit: reasons for applying the tool / what’s in it for me When: recommendation of when tool can be applied Steps: guide on how to apply tool 4 First Choice Pocket Guide First Choice Pocket Guide 5 INTRODUCTION DHL First Choice is a DHL’s worldwide program to drive continuous improvement of processes and services. ‘Everybody, Every Day and Everywhere a little bit Better’ has enabled us to become and remain the first choice of our customers. This passion for continuous improvement is part of our DNA and is anchored in our corporate culture. It has allowed us to be a global market leader in logistics for many years now. We are happy to share our expertise and experience with you; now you too can experience what the First Choice approach can do for your company and your customers. We have already guided many customers in this process. Goal of DHL First Choice The goal is to create greater efficiency in your services and optimize your processes, with the help of our DHL First Choice experts. Improvements that increase your business performance and strengthen trust in your company. It will also positively impact your customer’s experience with your brand.
    [Show full text]
  • Extension of the Lean 5S Methodology to 6S with an Additional Layer to Ensure Occupational Safety and Health Levels
    sustainability Article Extension of the Lean 5S Methodology to 6S with An Additional Layer to Ensure Occupational Safety and Health Levels Mariano Jiménez 1,2 , Luis Romero 2,* , Jon Fernández 2, María del Mar Espinosa 2 and Manuel Domínguez 2 1 Department of Mechanical Engineering, Technical School of Engineering—ICAI, Comillas Pontifical University, 25, 28015 Madrid, Spain 2 Design Engineering Area, Industrial Engineering School, National Distance Education University (UNED), 38, 28015 Madrid, Spain * Correspondence: [email protected] Received: 12 June 2019; Accepted: 11 July 2019; Published: 12 July 2019 Abstract: This paper proposes an expansion of the Lean 5S methodology, which includes the concept of Safety–Security as 6S. Implementation was done by a standardized process tested in a pilot area that is part of the Integrated Industrial Manufacturing System Laboratory at the Higher Technical School of Engineering (ICAI). The additional 6S phase (Safety-Security) thoroughly reviews all areas of an industrial plant by analyzing the risks at each workstation, which let employees be fitted out with protection resources depending on each of their personal characteristics and to guarantee the safety of the workstation by strictly complying with occupational safety and health and machinery use standards, which must hold a CE certificate of compliance. The main objective was to increase the scope of 5S methodology to respond to the occupational safety and health needs for machines required in optimizing production processes. It is important to remember that companies must guarantee that their employees use personal protection equipment (PPE) at their work posts or stations that protect them properly from risks to their health and safety and that cannot be prevented or sufficiently limited by using collective means of protection or by adopting work organization measures.
    [Show full text]
  • Application of the 5S-KAIZEN Approach in Improving the Productivity and Quality of the Healthcare System: an Operational Research
    Application of the 5S-KAIZEN Approach in Improving the Productivity and Quality of the Healthcare System: An Operational Research Naglaa Abdel Khalek El-Sherbiny1 (MD); Asmaa Younis ELsary1* (MD); Eman H. Ibrahim1 (MD) 1. Department of Public Health, Faculty of Medicine-Fayoum University, Egypt. A R T I C L E I N F O A B S T R A C T Article type: Introduction: Quality is an important index in various aspects of life. The Original Article 5S-KAIZEN method is widely applied for the improvement of work environments. This systematic approach is fundamentally used to enhance the Article history: quality of services in all types of organizations. The present study aimed to Received: 8-Agust-2017 assess the application of the 5S-KAIZEN approach in improving the quality of Accepted: 29-Agust-2017 care provision in hospitals and evaluate its effects on the job satisfaction of the healthcare providers. Keywords: Materials and Methods: This interventional, operational research was Approach conducted at a teaching hospital. In-depth interviews were performed to obtain Operational the viewpoints of the physicians, and group discussions were held for nurses in Quality order to assess their satisfaction with the implementation of the 5S-KAIZEN 5S-KAIZEN approach in the work environment. Staff Results: Patient-hospital cycle time decreased by more than 50% after implementing the 5S-KAIZEN approach. In addition, the healthcare professionals believed that applying the 5S-KAIZEN approach saved time, money, and efforts, while reducing their daily workload and stress. Conclusion: According to the results, the 5S-KAIZEN approach could improve the standards in the healthcare work environment, support the safe practices leading to high-quality and efficient care services, enhance productivity at a low cost, and increase the satisfaction of the healthcare staff with their professional image and communication with the other personnel.
    [Show full text]
  • Using Six Sigma and Lean Principles to Improve Laboratory Operations
    Using Six Sigma and Lean Principles to Improve Laboratory Operations Big Bang Makeover of the Clinical Laboratory: Key Lessons for Work Flow, Analyzers, and Service Improvements Atlanta, GA Purpose/Objectives • Purpose: – To provide an overview of using Six Sigma and Lean Principles in chartering, designing and implementing a full scale Lean project in a large laboratory setting. • Objectives: – Understand how each phase of DMAIC was used to execute a full scale Lean design effort – Understand which key Lean tools were used in measure/design/implementation – Understand how interactions of physical, process, technological, and organizational changes contribute to a large scale Lean effort. 1 Outline • Who we are • Why Improving Lab Operations is Important to Quest Diagnostics • The Journey • Key Learnings Who we are • Focus: – Patients – Growth – People • Vision: – Dedicated People Improving the Health of Patients Through Unsurpassed Diagnostic Insights • Company Background – 40,000+ Employees – 900+ Clinical Scientist PhDs/MDs – Patient Service Centers – Rapid Response to Esoteric Laboratories – 145 million patient encounters annually • Values: – Quality, Integrity, Innovation, Accountability, Collaboration, Leadership • Six Sigma/Lean Journey – 2000?2008 2 Why Improving Lab Operations is Important to Quest Diagnostics PATIENTS 1. Reduce Patient Anxiety Time 2. Reduce tests not performed PEOPLE 1. Shortage of technical workforce GROWTH 2. Staffing of night shift 1. Improve equipment utilization 3. Improve technical skills 2. Improve productivity 4. Reduce potential blood exposure 3. Improve supply utilization 5. Reduce ergonomic Injuries 6. Improve staff involvement The Journey 3 The Journey – Integrating Six Sigma Design DMAIC DMADV Lean Three Major Improvement Six Sigma Process Methodologies Management Measurement Systems Integration Complex project required adequate training/development Using DMAIC & Lean to Define Project PATIENTS 1.
    [Show full text]
  • Lean Six Sigma Rapid Cycle Improvement Agenda
    Lean Six Sigma Rapid Cycle Improvement Agenda 1. History of Lean and Six Sigma 2. DMAIC 3. Rapid Continuous Improvement – Quick Wins – PDSA – Kaizen Lean Six Sigma Lean Manufacturing Six Sigma (Toyota Production System) DMAIC • T.I.M.W.O.O.D • PROJECT CHARTER • 5S • FMEA • SMED • PDSA/PDCA • TAKT TIME • SWOT • KAN BAN • ROOT CAUSE ANALYSIS • JUST IN TIME • FMEA • ANDON • SIPOC • KAIZEN • PROCESS MAP • VALUE STREAM MAP • STATISTICAL CONTROLS Process Improvement 3 Lean Manufacturing • Lean has been around a long time: – Pioneered by Ford in the early 1900’s (33 hrs from iron ore to finished Model T, almost zero inventory but also zero flexibility!) – Perfected by Toyota post WWII (multiple models/colors/options, rapid setups, Kanban, mistake-proofing, almost zero inventory with maximum flexibility!) • Known by many names: – Toyota Production System – Just-In-Time – Continuous Flow • Outwardly focused on being flexible to meet customer demand, inwardly focused on reducing/eliminating the waste and cost in all processes Six Sigma • Motorola was the first advocate in the 80’s • Six Sigma Black Belt methodology began in late 80’s/early 90’s • Project implementers names includes “Black Belts”, “Top Guns”, “Change Agents”, “Trailblazers”, etc. • Implementers are expected to deliver annual benefits between $500,000 and $1,000,000 through 3-5 projects per year • Outwardly focused on Voice of the Customer, inwardly focused on using statistical tools on projects that yield high return on investment DMAIC Define Measure Analyze Improve Control • Project Charter • Value Stream Mapping • Replenishment Pull/Kanban • Mistake-Proofing/ • Process Constraint ID and • Voice of the Customer • Value of Speed (Process • Stocking Strategy Zero Defects Takt Time Analysis and Kano Analysis Cycle Efficiency / Little’s • Process Flow Improvement • Standard Operating • Cause & Effect Analysis • SIPOC Map Law) • Process Balancing Procedures (SOP’s) • FMEA • Project Valuation / • Operational Definitions • Analytical Batch Sizing • Process Control Plans • Hypothesis Tests/Conf.
    [Show full text]
  • Value Stream Mapping to Improve Workplace to Support Lean Environment
    MATEC Web of Conferences 135, 00032 (2017) DOI: 10.1051/matecconf/201713500032 ICME’17 Value Stream Mapping to Improve Workplace to support Lean Environment Ahmad Nur Aizat Ahmad.1,*, Te Chuan Lee.1 Rohaizan Ramlan.1 , Md. Fauzi Ahmad. 1, Norafifah Husin 2 and Mustaqqim Abdul Rahim.3 1Department of Production and Operation Management, Faculty of Technology Management and Business, Universiti Tun Hussein Onn Malaysia (UTHM), Malaysia 2Department of Industrial Engineering, Faculty of Mechanical Engineering, Universiti Teknologi Malaysia (UTM), Malaysia 3Department of Civil Engineering, School of Environmental Engineering, Universiti Malaysia Perlis (UniMAP), Malaysia Abstract. In recent years, lean manufacturing is being followed by various sectors in order to keep their competitiveness in the global markets. Lean manufacturing plays a vital role in improving the efficiency of operation by eliminating or reducing wastes. Nonetheless, most of small and medium enterprises (SMEs) lack sufficient knowledge or information on the benefits of implementing lean manufacturing. The main objective of this study is to apply value stream mapping, one of lean manufacturing tools, for improving the productivity in a SME by eliminating non-value added activities. In this study, lean manufacturing was adopted at a SME, particularly a food industry. Value stream mapping was served as main tool to identify the wastes and improvement opportunities in production line. Subsequently, different lean manufacturing tools such as Kaizen Burst, one piece flow, and 5S were applied to eliminate or reduce identified wastes. Based on the future state value stream mapping, final results showed that the total operation time and non-added value activities time were successfully decreased from 1993 seconds to 1719 seconds, and 234 seconds to 104 seconds, respectively.
    [Show full text]
  • Using DMAIC in Improvement of Customer Satisfaction and Facilities Provided at Commuter Stations
    International Journal of Academic Research in Business and Social Sciences 2016, Vol. 6, No. 12 ISSN: 2222-6990 Using DMAIC in Improvement of Customer Satisfaction and Facilities provided at Commuter Stations Roslina Mustapha1, Nurul Fadly Habidin2 1Department of Business Management, Faculty of Management and Economics, Universiti Pendidikan Sultan Idris, 35900 Tanjung Malim, Perak, Malaysia 2Department of Management and Leadership, Faculty of Management and Economics, Universiti Pendidikan Sultan Idris, 35900 Tanjong Malim, Perak, Malaysia DOI: 10.6007/IJARBSS/6-i12/2564 URL: http://dx.doi.org/10.6007/IJARBSS/v6-i12/2564 Abstracts This paper discusses the use of six sigma approach to improvement of customer service and facilities at commuter stations. The management of commuter stations should be sensitive to the needs and desires of the passengers. In this study, DMAIC approach taking into accounts the views of the customer (VOC) to the dissatisfaction of commuter services and facilities available at commuter stations. Keywords: Six sigma, DMAIC, customer satisfaction, business management 1. Introduction The performance of a business, whether private or public sector is depends on customer satisfaction. For commuter service almost 20 years of presence in Malaysia, there are still some problems, especially to people with disabilities (PWDs) who want to use the commuter service. Using the six-sigma approach is one way to solve the problem of quality of service. Problem solving is an activity to change what is actually happening to what is supposed to happen (Evans & Lindsay, 2007). People with disabilities are not left behind in the services for commuters as it is one of the convenient public transports, safe and cheap.
    [Show full text]
  • Lean Manufacturing and Reliability Concepts the Concepts Contained Within Lean Manufacturing Are Not Limited Merely to Production Systems
    From the Reliability Professionals at Allied Reliability Group R LEAN MANUFACTURING & RELIABILITY CONCEPTS Inside: Key Principles of Lean Manufacturing 3 Types of Inspections for Mistake-Proofing A MUST-READ GUIDE FOR MAINTENANCE AND RELIABILITY LEADERS Allied Reliability Group © 2013 • 1 COPYRIGHT NOTICE Copyright 2013 Allied Reliability Group. All rights reserved. Any unauthorized use, sharing, reproduction or distribution of these materials by any means, electronic, mechanical, or otherwise is strictly prohibited. No portion of these materials may be reproduced in any manner whatsoever, without the express written consent of the publisher. To obtain permission, please contact: Allied Reliability Group 4200 Faber Place Drive Charleston, SC 29405 Phone 843-414-5760 Fax 843-414-5779 [email protected] www.alliedreliabilitygroup.com 2nd Edition November 2013 2 • Allied Reliability Group © 2013 Lean Manufacturing TABLE OF CONTENTS Introduction .............................................................................................4 Part 1: 5S................................................................................................6 Part 2: Muda ......................................................................................... 11 Part 3: Key Principles of Lean Manufacturing ......................................16 Part 4: Poka-Yoke .................................................................................19 Kaizen...................................................................................................25
    [Show full text]
  • "5S" Strategy by Using PDCA Cycle for Continuous Improvement of the Manufacturing Processes in Agriculture Industry
    Int. J. Research in Industrial Engineering, pp. 10-23 Volume 2, Number 3, 2013 International Journal of Research in Industrial Engineering journal homepage: www.nvlscience.com/index.php/ijrie The "5S" Strategy by Using PDCA Cycle for Continuous Improvement of the Manufacturing Processes in Agriculture Industry B. Singh Sidhu 1, V. Kumar 2, A. Bajaj 3,* 1ME Department, GZS PTU Campus, Bathinda. 2ME Department, GTBKIET, Malout. 3GZS PTU Campus, Bathinda. A R T I C L E I N F O A B S T R A C T Article history : The global marketplace has witnessed an increased pressure from Received : customers and competitors in manufacturing .In this age of agile May 2, 2013 manufacturing the global competition characterized by both Revised : technology push and market pull had forced the companies to achieve July 13, 2013 world-class performance through continuous improvement in their Accepted : products and processes, reduction in cost, reduce wastes, increase September 25, 2013 quality, increasing of effectiveness, safety increasing, reduction of the pollution, increase decision making power and improved methodology. To want all this changes, there is need to adopt new the Keywords : management system. In management system there are many types of 5S, Productivity, FIFO, techniques. The present work is dedicated to study and implement 5S Two Bin System, Takt Methodology. In this work, proper system will be analyzed to reduce Time, Cycle Time. the wastes, reduction in cost, processes, and increase decision making power by implementing 5S techniques. Apart from this, theoretical results compared with original data from industry before and after implementation. 1.
    [Show full text]
  • Green Belt Training Index
    P600 - Green Belt Training Index Term Module & Slide(s) 5 Whys Analyze 4.13 - 4.19, 7.3, 7.6, 7.9 5 Whys, Template Analyze 4.18, 7.3, 7.6, 7.9 5S Improve 2.93 - 2.118, 6.5, 6.7, 6.12, Control 2.8 - 2.9, 4.8 5S Assessment Template Improve 2.116 - 2.117, 6.12, Control 2.8 5S, Set In Order Improve 2.99, 2.105 - 2.108 5S, Sort Improve 2.99, 2.101 - 2.104 5S, Standardize Improve 2.99, 2.11 - 2.13 5S, Steps of Improve 2.99 5S, Sustain Improve 2.99, 2.114 - 2.115 8 Wastes Intro 3.1 - 3.13, 7.2, 7.6, 7.8, 7.9 8 Wastes Check Sheet Template Intro 7.2, 7.6, 7.8-7.9 8 Wastes, Defects Intro 3.8 8 Wastes, DOWNTIME Acronym Intro 3.6 - 3.8 8 Wastes, Elimination of Intro 3.9 - 3.11 8 Wastes, Extra-Processing Intro 3.8, 3.12 8 Wastes, Inventory Intro 3.8 8 Wastes, Motion Intro 3.8, 3.11 - 12 8 Wastes, Non-Utilized Talent Intro 3.8 8 Wastes, Overproduction Intro 3.8, 3.12 8 Wastes, Transportation Intro 3.8, 3.12 8 Wastes, Waiting Intro 3.8 Define 5.9 - 5.14, 6.9, Measure 5.11, Analyze 7.9, Improve 6.12, A3 Control 6.9 A3, Template Define 5.12, Measure 5.11, Improve 6.12 Affinity Analysis Define 3.23 - 3.26, Measure 2.24, Analyze 4.3 - 4.6 Alignment Model, Team Dynamics Define 5.43 - 5.45, 6.6 1 P600 - Green Belt Training Index Term Module & Slide(s) Alternative Hypothesis Analyze 6.11 - 6.14 Analogy, Brainstorming Technique Improve 2.12 Analyze Phase Intro 5.6, Analyze 1.1 - 7.10 Analyze Phase, Challenges Analyze 7.5 Analyze Phase, Deliverables Analyze 7.9 Analyze Phase, Steps Analyze 1.4 Analyze Phase, Tollgate Checklist Analyze 7.8 Analyze Phase, Tools
    [Show full text]
  • Lean Six Sigma Approach to Improve the Production Process in the Mould Industry: a Case Study
    View metadata, citation and similar papers at core.ac.uk brought to you by CORE provided by Repositório Científico do Instituto Politécnico do Porto QUALITY INNOVATION PROSPERITY / KVALITA INOVÁCIA PROSPERITA 23/3 – 2019 103 Lean Six Sigma Approach to Improve the Production Process in the Mould Industry: a Case Study DOI: 10.12776/QIP.V23I3.1334 António M.H. Pereira, Miguel R. Silva, Mercedes A.G. Domingues, José C. Sá Received: 01 November 2019 Accepted: 19 November 2019 Published: 30 November 2019 ABSTRACT Purpose: The purpose of this article is to explore the optimization of internal process is assumed as a critical factor to be capable of answering to the moulds industries. Consequently, it has been considered essential to adopt high-valued methodologies to support tooling industry in order to achieve global competitive advantages. For that purpose, this work aims to apply LEAN principles and techniques to support mould design and manufacturing processes. Methodology/Approach: The methodology used was based on PDCA/DMAIC, with the following stages: Define, Measure, Analyze, Improve and Control. For each stages was taken some of Lean Six Sigma techniques, such as Continuous Improvement, Value Stream Mapping, Pareto analysis and Overall Equipment Effectiveness. Findings: This study results was revealed that there are many areas on the organizations in the Mould Industry, when they utilize otimizations tools obtain hugt successes. With the Pareto analysis was carried out to show that events that contributes the most to the stops. The results were: unavailability of the operator (16.4%), programming the machine (14.4%) and tool exchange (12.4%) In the case of this Mould Industry study was obtained for the CNC machines studies, with the implementation of Lean Six Sigma tools as obtained a improvement about 20% of global OEE.
    [Show full text]
  • Lean Thinking, PDCA, 5S, Automobile Service Industry
    Journal of Mechanical Engineering and Automation 2016, 6(5A): 40-48 DOI: 10.5923/c.jmea.201601.08 Enhancing the Performace of an Automobile Service Industry: Lean Thinking Approach Shreeranga Bhat1,*, Jnanesh N. A.2, Prashanth P. Kamath1, Rajat R. Nayak1, Nithin M. D’souza1 1Department of Mechanical Engineering, St Joseph Engineering College, Mangaluru, India 2Department Mechanical Engineering, KVG College of Engineering, Sullia, India Abstract The objective of the research is to identify challenges in an automobile service center and to determine optimal solutions to improve the overall performance. More specifically the research has the following objectives: To increase the productivity using Lean strategy; To reduce the wastage, non-value added activities; To create an easy and simple work environment; To develop a 5S Auditing control system to sustain the improved process; To educate Janitorial level people about benefits of using Lean strategy. The research reported in this research is based on a single case study carried out in an organization using Lean PDCA (Plan-Do-Check-Act) approach, 5S tool and its applications to enhance the productivity. The root causes for the problem in the servicing of cars has been identified through the data based analysis at different stages in the research. The process parameters have been optimized and measured for sustainability in the process. Lean strategy resulted in reduced amount of energy and non-value added activities associated with its production processes. Further, research resulted in the creation of a visual workplace, which has enhanced the production atmosphere, and created a simple and easy process design to lay the foundation to a future of continuous improvement.
    [Show full text]