LeanPrinciples across the Supply Chain
LeanThinking: Principles and Building Blocks
FrankL. Chelko, The Pennsylvania State University,
Definitionof lean:
Identificationand Elimination of Waste & Process Acceleration Speed
TheLean Philosophy
- Theessence of lean is the systematicidentification and eliminationof waste in order to shorten lead-time to the customer.
- All systems contain waste
- Eachsystem is unique
- Waste are those elements of thesystem that do not add value: Allnon value-added
- Value is defined as that whichthe customer is willing to pay for
Goal: Eliminate “Wastes”
Japanese“Muda” the 8 Wastes
- Overproduction:Making more, earlier, or faster
- Inventory:Any supply in excess of a one0piece flow
- Defectiveproduct: inspection, sorting, scrapping, replacement or repair
- Over-processing:Efforts that add no value
- Waiting:Idle time waiting for manpower, material, machinery/tools, measurement,information, etc
- People:Underutilization of physical, mental, creative, skills, experience, etc.
- Motion:Any movement of people, equipment, that does not add value
- Transportation:Movement of parts/material in plant.
TheBroader “Enterprise Perspective”
- EnergyResources: inefficient/excessive use of power, heat, cooling, etc.
- Environmental(Green): Pollutants/Emissions (chemical, nuclear, biological, material)
Building Blocks of “Lean”: Basic Tools andTechniques
| Continuous Improvement | Value Stream Mapping |
| Pull/Kanban | Celluar (cells with worker routes) /Flow | Total Productive Maintenance |
| Quality at Source | Point of Source Storage | Quick Changeover |
| Standardized work | Batch reduction | Teams |
| 5S System*1 | Visual Controls (i.e. Andon (lamp) display) | Streamlined layout*2 |
| Change Improvement |
Additional Tools & techniques
- Poka-Yoke-foolproofing
- Jidoka:Automation inspection
- KaizenBlitz: Continuous improvement process
*1) 5S System plus 1: A systemfor workplace organization and standardization
(http://en.wikipedia.org/wiki/5S_(methodology))
- Sorting: Organizing and discarding things not used
- Storage:neatness/equipment layout in the workplace
- Shining:work place cleanliness
- Standardizing:
- Sustaining:discipline toe maintain the other four
- Safety:freedom from conditions which can cause injury of death to personnel, damage toor loss of equipment or property
*2) process flowchart à value streamlined layout