Establish the need for change
Assess your company
- define product groupings and current processes
- specify value
- identify the value stream (current and future state map)
Educate at all levels
Support the learning of the lean tools and methods
Implement the lean tools and methods
- organize the workplace (5S)
- improve plant layout for flow manufacturing
- reduce lot sizes, setup times, lead times and inventory
- develop a pull system
- standardize operations
- improve quality
- improve maintenance
Modify the organization structure: everybody’s job is going to change, people from the shop floor to the top floor will work differently and in departments that are structured differently
Establish improvement metrics
Seek perfection
Click Here to access The Lean Manufacturing Coaching Program.
August 21st, 2008
CMMS Definition
Computerized Maintenance Management System: computer replaces manual systems
Basic Modules
- Asset register
- documentation
- equipment data management
- multi-level hierarchical filing system
- Work order management
- History file
- required for feedback
- maintenance of work preparations
- reporting
- Spare parts inventory control
Optional modules
- Budget analysis
- Invoice / ordering control
- Condition Based Maintenance Manager
- Failure analysis
Trends
- Internet-enabled
- bringing information and training to the shop floor
- transferring analysis data to equipment suppliers
- online equipment monitoring
- purchasing of spare parts (e-procurement)
- software vendors will host CMMS on their own servers (Application Service Providers)
- Data Input:
- Use of handheld computers by technicians
- Interfacing with bar code terminals
- Integration of Supply Chain Software and CMMS
Click Here to access a Powerpoint Presentation about Maintenance Management (78 slides).
August 19th, 2008
Value
In lean manufacturing, the value of a product is defined solely by the customer.
Value-adding activities transform the product closer to what the customer wants, non value-adding activities don’t create customer value.
Anything that is not value-adding is defined as waste.
Value Stream
The value stream is an end-to-end collection of processes that create value for the customer.
The value stream includes
- people
- tools and technologies
- physical facilities
- communication channels
- policies and procedures
Value Stream Mapping
Value Stream Mapping is a method to describe the flow of material and information through the production system.
By graphically portraying the process, one is able to see where value is added and value is lost.
The ratio of value added to total lead time is figured by documenting the current lead time, inventory levels and cycle times.
The visual representation allows to see where costs can be reduced and improvements can be made.
A future state can be designed where wasted steps are left out, and continuous flow and pull production are introduced.
Click Here to access 2 Value Stream Mapping Presentations (84 slides).
August 13th, 2008
Reliability: the probability that equipment will not fail in a given time period.
Maintenance: Any activity carried out on an asset in order to
- ensure that the asset continues to perform its intended functions
- repair the asset
Reliability Centered Maintenance (RCM): a methodology used to determine the right maintenance tasks, to ensure that any physical asset or system continues whatever its users want it to do, in its present operating context.
Click Here to access an RCM Powerpoint Presentation (54 slides).
August 12th, 2008
Features of the Online Supplier Evaluation Tool
- You can evaluate your suppliers or vendors online
- There are 20 supplier evaluation criteria
- You can give a weight to each of the supplier criteria
- You can give a score for each of the supplier criteria
- A total score will be calculated, and the result of the supplier evaluation can be printed out
- This tool will help you with your supplier or vendor selection
Get access to the Online Supplier Evaluation Tool
July 29th, 2008
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