Tag: Lean tools

What is Value Stream Mapping (VSM)

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Value Stream Mapping (VSM) is a Lean tool, to visualize the various steps and their contribution to the overall process.
Value
When a product or service has been perceived or appraised to fulfill a need or desire–as defined by the customer–the product or service may be said to have value or worth. Components of value may include quality, utility, functionality, capacity, aesthetics, timeliness or availability, price, etc.
Value Stream
All the activities (both value-added and non-value added) required within an organization to deliver a specific service; “everything that goes into” creating and delivering the “value” to the end-customer.
Process Map
A visual representation of the sequential flow of a process. Used as a tool in problem solving, this technique makes opportunities for improvement.
Value Stream Mapping A graphical representation of all tasks and activities needed to transform input materials and information into an output. 
Value Stream Analysis – The identification of all the specific activities occurring along the value stream, represented pictorially in a value stream map; see waste, unevenness, and overburden, size the opportunity, share a vision, communicate visually, permission to change, predict results
Non Value Added (NVA) – Those process steps in a Value Stream that take time, resources or space, but do not transform or shape the product or service to meet the needs of the customer 
Value Added Activity – An activity can qualify to be value adding, if the customer cares, perceptable change and first time right.
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Originally posted 2012-08-26 08:06:00.

What is Rapid Improvement Event (RIE)

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Rapid Improvement Event (RIE) is a 4-5 day process utilizing a team based methodology to apply the lean tools for seeing waste and making immediate improvement. The focus in a Rapid Improvement event is to work on the set up time or the Changeover time.
Set-up Time
Work required to change over a machine or process from one item or operation to the next item or operation; can be divided into two types:
1. Internal: set-up work that can be done only when the machine is not actively engaged in production OR
2. External: set-up work that can be done concurrently with the machine or process performing production duties
Changeover Time
As used in manufacturing, the time from when the last “good” piece comes off of a machine until the first “good” piece of the next product is made on that machine. Includes warm up, first piece inspection and adjustments. 
The set up time and change over time are two of the biggest challenges to maintain a continuous flow of the work. this is one of lean tools effectively used by General Electric (GE)
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Originally posted 2012-08-26 07:50:00.

Cellularization or Cellular Manufacturing

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In lean Manufacturing, Cellurization or Cellular Manufacturing is used to great affect. These are the Quality control tools used for cycle time reduction and set up time reduction.

Cellular Manufacturing
An approach in which manufacturing work centers (cells) have the total capabilities needed to produce an item or group of similar items; contrasts to setting up work centers on the basis of similar equipment or capabilities, in which case items must move among multiple work centers before they are completed. Each work center is capable of producing from start to finish of a product. Since very little movement is involved, this will help in optimizing the cycle time. 

Cellularization
Grouping machines or processes that are connected by work sequence in a pattern that supports flow production. Her the focus is on flow of the work, where there is very little movement of the work in the shop floor. Looking at a cycle time point of view the improved flow will certainly help in faster production. 
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Originally posted 2012-08-26 07:44:00.

De-bottlenecking process and improving throughput

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De-bottlenecking is  one of the very good lean tools focus on reducing cycle time and improving throughput. One of the important toll used is to study the bottlenecks in the system and improving throughput. A systemic approach is taken in studying, analyzing and acting on the bottlencks. A similar approach is taken in the theory of constraints also.

Bottleneck- Definition

The place in the value stream that negatively affects throughput; as a resource capacity limitation, a bottleneck will not allow a system to meet the demand of the customer.

De-bottlenecking:

De-bottlenecking essentially involves studying the bottleneck in the system and Improving the throughput rate of the process by working on optimizing the utilization of the bottleneck. 

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Originally posted 2012-08-26 07:33:00.

What is Autonomation

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Autonomation:
Described as “intelligent automation” or “automation with a human touch.” If an abnormal situation arises the machine stops and the worker will stop the production line. Prevents the production of defective products, eliminates overproduction and focuses attention on understanding the problem and ensuring that it never recurs.
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Originally posted 2012-08-26 07:14:00.

What is Andon

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Andon – Definition
A device that calls attention to defects, equipment abnormalities, other problems, or reports the status and needs of a system typically by means of lights – red light for failure mode, amber light to show marginal performance, and a green light for normal operation mode.
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Originally posted 2012-08-26 07:00:00.

What is A3 thinking

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A3 thinking- Definition

Forces consensus building; unifies culture around a simple, systematic methodology; also becomes a communication tool that follows a logical narrative and builds over years as organization learning; A3 = metric nomenclature for a paper size equal to 11”x17”

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Originally posted 2012-08-26 06:56:00.