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LEAN CONCEPTS

The Thinking Approach

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TECHNICAL THINKING TO

DEVELOP A LEAN SYSTEM

Tools to Drive Kaizen Activity

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TECHNICAL TOOLS

Tools to

Improve

Tools to

Measure

Two key questions

UNDERSTANDING SKILLS

When do I need them? What are they?

LEAN TRANSFORMATION

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TOOLS TO IMPROVE

Stability

Problem Solving

Standardized Work

Jidoka

Heijunka

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JIDOKA

TOOLS TO IMPROVE

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BUILD IN QUALITY

× Only inspect finished goods

× No feedback to operations

generating the defects

× Extra rework operation / cost

JIDOKA

A C B

Rework

Scrap

Ship

Inspect

C B A

Traditional Thinking

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BUILD IN QUALITY

Do not pass defects – fix in

process

Immediate quality feedback

Defects are found at the source

Each Process only

ships quality product

C

A

B A

C B

Ship

JIDOKA

Lean Thinking

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HOW WE BUILD IN QUALITY

1. Make abnormalities visible

2. Call for help quickly

3. Immediate response

4. Implement countermeasure

2

Call for help

Quick

Response

3

Countermeasure 4

1

JIDOKA

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TOOLS TO BUILD IN QUALITY

Developed from supervisors need to

know when / where problems occur

Tool for visual control

Practical, easy, inexpensive

Team member input

Go and see!

ANDON POKAYOKE Human

[Flag]

Machine

[Light]

Fixture

JIDOKA

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SEPARATE MAN FROM MACHINE

1 Man – 1 Machine

1 Man – Several Machines

Unclamp Clamp

MAN MACHINE

Wait on

machine

Unclamp Clamp

MAN

MACHINE

Unclamp Clamp

MAN MACHINE

One cycle time

Turret A

Turret B

JIDOKA

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JIDOKA EXAMPLE

JIDOKA

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WHY JIDOKA MATTERS

PROCESS

Call for help

Quick

Response

Countermeasure

1

2

3

4

Build in quality

More effective use of

human resources

Highest Quality

Lowest Cost

Shortest Lead Time 1 Man – 1 Machine

1 Man – Several Machines

Unclamp Clamp

MAN MACHINE

Wait on machine

Unclamp Clamp

MAN

MACHINE

Unclamp Clamp

MAN MACHINE

On cycle time

Turret A

Turret B

JIDOKA

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QUESTIONS

CLOSING DISCUSSION