Lean Principles - BSI Education.PPTVIP

Lean Principles Being Fast, Flexible, Economic Author: Dr Rhys Rowland-Jones Session Plan: What is lean? How does lean work? Who is lean applicable to? 5 principles of lean The Toyota Production System Taiichi Ohno’s 7 Wastes 7 service wastes 5 S’s What is lean? Lean manufacturing was developed by the Japanese automotive industry, with a lead from Toyota and utilising the Toyota Production System (TPS), following the challenge to re-build the Japanese economy after World War II. The concept of lean thinking was introduced to the Western world in 1991 by the book “The Machine That Changed the World” written by Womack, Jones, and Roos. Lean is a philosophy that seeks to eliminate waste in all aspects of a firm’s production activities: human relations, vendor relations, technology, and the management of materials and inventory. How does Lean work? Considers an ‘end to end’ value stream that delivers competitive advantage. Seeks fast flexible flow. Eliminates/prevents waste (Muda). Extends the Toyota Production System (TPS). Who is Lean applicable to? Lean is principally associated with manufacturing industries but can be equally applicable to both service and administration processes. Currently it is also being adopted by the food manufacturing and meat processing sectors. It’s not a new phenomenon, Japanese auto manufacturers have been developing Lean for over 50 years. 5 principles of Lean Value - specify what creates value from the customer’s perspective. The value stream – identify all the steps along the process chain. Flow - make the value process flow. Pull - make only what is needed by the customer (short term response to the customer’s rate of demand). Perfection - strive for perfection by continually attempting to produce exactly what the customer wants. Value Any process that the customer would be prepared to pay for that adds value to the product. The customer defines the value of product in a lean supply chain. Value-adding activities transform