Professional Documents
Culture Documents
What is Waste?
Waste is anything
that happens to a
product that does not
add value from the
customers
perspective
Products being stored,
inspected or delayed,
products waiting in
queues, and defective
products do not add
value
Seven Wastes
Origins
Lean Manufacturing is
sometimes called the
Toyota Production
System (TPS)
because Toyota
Motor Companys Eiji
Toyoda and Taiichui
Ohno are given credit
for its approach and
innovations
Underlying Principles to
TPS
Kanban
Kanban Example
Supermarket Ordering System
Benefits of Kanban
Lean Manufacturing
Advantages and
Disadvantages Disadvantages:
Advantages:
Increased overall
productivity
Reduced amount of
floor space required
Reduced
manufacturing lead
time
Improved flexibility
to react to changes
Improved quality
People
Transition to Lean is
difficult since a
company must build a
culture where learning
and continuous
improvement are the
norm.
Success of lean
requires the full
commitment and
involvement of all
employees and of the
companys suppliers.
Traditional
Lean
Improvement
Communication
Quality &
Coordination
Teamwork
Inhibited
Enhanced
Effective Teams
Motivation
Negative, Extrinsic
Positive, Intrinsic
Strong Motivation
Skill Range
Narrow
Broad
Job Enrichment
Supervision
Difficult and
Fragmented
Fewer Supervisors
Traditional
Lean
Improvement
Response
Weeks
Hours
70-90%
Customization
Difficult
Easy
Competitive
Advantage
Delivery Speed
Weeks-Months
Days
70-90%
Delivery
Reliability
Erratic
Up to 90%
Delivery
Quantities
Large Shipments
JIT as Required
Locks in JIT
Customers
Quality
Erratic
Delighted
Customers
Economics
Reduction of Inventory
Reduced Waste