Principals of Lean Manufacturing

When was the last time you heard about Toyota laying off employees? When Japanese manufacturers faced declining resources after World War II, they responded by embracing new, lower cost, manufacturing practices. Early leaders, such as the Toyota Motor Company, developed a process-focused production system now known as the "Toyota Production System," or "Lean Manufacturing." Essentially, the process eliminates activities that do not add value to the product the customer receives.

With your commitment, CITEC's Lean-certified engineers can help your North Country company gain the advantage you need over competitors with improved product quality, cost, lead times, and customer service.

Companies that have embraced Lean have experienced significant results. Numerous surveys of these companies have reported major sales growth and market share gains based on:

• 60% reduction in cycle times
• 98% on-time deliveries
• 80% reduction in floor space
• 40% WIP reduction
• 50% improvement in quality
• 95% machine availability
• 80% reduction in changeovers

CITEC follows a systematic approach to eliminating waste. When the process is completed, you will have the foundation to become a World Class Manufacturer and will have made significant strides in reaching that goal. Implementing a Lean process at your company will result in cost savings that directly benefit your bottom line.

Tools of Lean

Value Stream Mapping - CITEC performs a review of the manufacturing processes with input from staff and production personnel. Through a series of specific fact finding questions, CITEC takes the information provided and creates a "current state" map and a "future state" map. These maps provide a visual representation of your operation and what it could look like. The future state map identifies non-value added operations, proposes potential steps for elimination, and estimates potential savings (time, labor, inventory, etc.).

Kaizen Events - three- to five-day team-oriented problem-solving efforts focused on a specific area. Your management and production personnel determine the scope of the project based on their experience. In some cases, CITEC may need to develop a Value Stream Map to help define the project. CITEC follows these steps: chart what is currently being done, measure (inputs/outputs), eliminate non-value-added activities, chart the new process and train operators, measure results, and celebrate accomplishments. Team member training occurs throughout each step of the process.

Setup Reduction - Quick changeover from one process to another is crucial in reducing batch sizes, increasing material flow, reducing inventory, reducing lead times, and reducing rework, along with many other benefits. CITEC presents and applies a systematic method that ensures success in reducing process changeover or machine setup. a process or machine in your facility is targeted for setup reduction up-front. CITEC then coaches the employees through the process of using the principles and methods learned to reduce setup time on the chosen processes and machines in your facility.

Cellular Manufacturing - This is an approach that helps companies build a variety of products for their customers with as little waste as possible. In cellular manufacturing, equipment and workstations are arranged in a sequence that supports a smooth flow of materials and components through the process, with minimal transport or delay. CITEC analyzes your production operation and products for the purpose of creating "families" based on either products or processes. CITEC then works with your employees to set up a flow/cellular manufacturing process that optimizes your operation.

Pull/Kanban Systems - visual signals for work to be performed. The objective is to control inventory and make only what is needed when it is needed. A Kanban is a visual management tool directing information and material flows throughout your organization based on signals driven by customer orders. These systems increase communication, reduce the necessity for micromanaging, simplify the decision-making process of what to do next, and much more.

Visual Workplace - sharing of information vital to the task at hand with the people who need it without speaking a word. It begins to create a workplace that is self-explaining, self-regulating, and self-improving, where what is supposed to happen does happen on time, every time. There are many aspects to creating a visual workplace and CITEC walks you through a proven systematic approach. Building on success, CITEC helps you harvest the "low hanging fruit" first and then systematically guides you through to the poka-yoke (mistake proof) stage.

5S Workplace System - CITEC uses the 5S program:
Sort what is not needed, sort through, then sort out, "when in doubt throw it out."
Straighten what must be kept, make it visible and self-explanatory so everyone knows what goes where.
Shine everything that remains. Clean equipment, tools, work areas, etc.
Standardize throughout the facility. Make it more automatic.
Sustain through discipline and goal-setting. Make it a way of life.

Standardized Work - operations safely carried out with all tasks organized in the best known sequence and using the most effective combination of resources: people, materials, methods, and equipment.

Plant Layout - the most efficient placement of equipment and workstations for workers to perform their tasks without excess motion or movement of product and raw materials.

Quality @ Source - catching defects before the next value-added step is performed. Defects are identified and fixed before the next process. Root causes of problems are easier to identify.

Batch Size Reduction - run product in the smallest amount (one-piece being the ideal) to increase flexibility, reduce inventory, and eliminate quality defects and excess rework.

Point of Use Storage (POUS) - all material is stored where it is going to be used in the process.

One Piece Flow - simply put, "make one, use one." One-piece flow is the state that exists when products move through a manufacturing process one unit at a time, at a rate determined by the needs of the customer.

Keys to Lean Success

In order to achieve a successful lean implementation, you will need to effectively prepare and motivate your workers through training. CITEC's experts can provide that training to your staff based on your unique needs -- either on-site or off, over various shifts, etc.

Contact a member of our Lean Team -- Eric Myers, Jim Myers, John Pinkerton or Terry Wiley -- to get started on your Lean Pathway to Success today.