Professional Documents
Culture Documents
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Competing in the Marketplace
What factors are important to the customer?
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Shrinking Lead Times
Order Lead Times Manufacturing Lead Times Delivery Lead Times
Reducing the overall time from receiving the order to delivering the product makes your company more responsive to the customer. This can become the deciding factor when the customer makes their selection. As can be seen, manufacturing is only one part of the entire process. Inputting, processing, and issuing orders is an area for improvement, as well as, assembly, loading and delivery to the customer`
John Deere Supplier Development
Kaizen Training
Wheres the Time in Lead Time
This timeline represents an overall lead-time, with very little time spent on adding value to the product.
Non-Value Added Time (NVA) 99% of Total Lead time Value Added Time (VA) 1%
Results of Common Improvement efforts, did not improve response time. VA time is reduced, but, the costs for those improvements in lead time was substantial.
John Deere Supplier Development
Kaizen Training
Wheres the Time in Lead Time
When we look at attacking the NVA Activities in the Timeline and compare that to the original timeline:
Greatest Opportunities are actually here!
Non-Value Added Time (NVA) 99% of Total Lead time NVA Time 95% of Total Lead time VA 5%
Great Job!!
Kaizen Training
Different Types of Activities
Being able to tell the difference between NVA and VA activities is an important step in the Improvement Process.
An activity that changes raw material to meet customer expectations. Those activities that take time, or occupy space but do not add to the value of the product.
You must ask yourselves Would you as a customer be willing to pay for any NVA activity being performed to that NEW 4x4 Pickup you just ordered?
Kaizen Training
Some examples NVA Activities:
Walking
Unnecessary stock on hand Transporting parts Waiting on machine cycle Generating useless reports Unnecessary motion
A definition: Destroy, in our minds, the concepts and techniques of manufacturing that we practice today. Create a vision of what our production system and manufacturing techniques should be.
We must avoid the urge to discover more sophisticated and technological solutions to tasks we shouldnt be doing at all.
Kaizen Training
Basic Rules for Change
Keep an open mind to change No such thing as a dumb question or idea Avoid spending money (Capital expense should be a last resort) Maintain a positive attitude Dont make excuses & question current practices
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Steps on Team Development
Forming This is the development of a multi-functional
team with a variation of backgrounds and knowledge
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What is TAKT Time?
TAKT time is how many minutes or seconds are needed to make one part when considering the daily volumes, to be produced in that workcell and the total time available to perform the job.
TAKT time is NOT the time it takes to manufacture the product. It is based on customer demand.
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Kaizen Training
TAKT Time Calculation
Production Time Available / Period
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TAKT
or 27,300 secs.
TAKT Time:
54.6 secs.
John Deere Supplier Development
Kaizen Training
The 5S Housekeeping Standards
First Step towards Continuos Improvement
The aim of 5S is to create an atmosphere to keep a clean, organized, safe and efficient workplace for everyone.
The foundation for the practice of 5S, comes from a Japanese program derived from these words, seiri, seiton, seiso, seiketsu and shitsuke. The 5Ss are a conventional approach towards maintaining and improving the work place. The following words have been chosen for the 5S acronyms.
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Sort
Straighten
Sanitize (Safety)
Sustain
Sweep
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Meaning of the 5Ss
Sort
Straighten
Examine everything at the workplace & identify what is needed and what can be discarded
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Organizing the way things are put away with efficiency, quality, and safety in mind. Need to decide where and how things should be put away and what rules should be obeyed to insure that it is maintained. Sweeping, scrubbing and cleaning of the building, machines, fixtures & tools so that all areas of the workplace are neat & tidy. This leads to early detection of mechanical problems before they become major breakdowns. Machines cry!
John Deere Supplier Development
Sweep
(Scrubbing clean)
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Meaning of the 5Ss
Sanitize
(Safety)
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Insuring that each workplace is properly designed for safety. This is to protect every member from the dangers during the performance of their assigned tasks.
Developing the practice necessary to continually participate in the 5S process. This requires that each of the Ss become a personal habit. This is the most difficult of the 5Ss, but it is the most important factor in achieving long term success. Establishing routines and procedures for maintaining and improving on the first four (Ss), incorporating visual management tools.
John Deere Supplier Development
Sustain
(Standardize)
Kaizen Training
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WASTE
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Do MORE with LESS
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Staffing
Waste
Productivity
Productivity
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SHIFT MINDSET
CURRENT THINKING REQUIRED THINKING
Processing Transportation
WASTE
WASTE NOT DEFINED REACT TO LARGE EXAMPLES REACTIVE IMPROVEMENT
Inventory
Waiting
WASTE IS "TANGIBLE IDENTIFY MANY SMALL OPPORTUNITIES -LEADS TO LARGE OVERALL CHAGE CONTINUOUS IMPROVEMENT
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ELEMENTS OF WASTE
Definition
1. Transportation - Transporting farther than necessary or temporarily locating, filing, stacking and moving parts (people, paper, information) is waste. 2. Correction - Doing something over is waste. 3. Overproduction - Generating excess paper or information, or generating information or paper too soon in a process is waste.
Example
1. Transportation - Carrying Tools to Point of Use
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ELEMENTS OF WASTE
Definition
4. Motion - Unnecessary work movements are a form of waste.
Example
4. Motion - Tools in drawers
5. Waiting - Waiting for people, 5. Waiting - Meetings to start paper and information is waste it stops work. 6. Inventory - Too much of anything is waste. 7. Processing - this is waste in the process itself. Redundant activities 6. Inventory - Supplies
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Process requires ongoing inspection and enforcement to ensure Standardized Work is being followed
Standards
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Enforce
Inspect
Identify Waste
- Following standards will only maintain, not improve, the process. - Improvement focuses on the entire process.
John Deere Supplier Development