ImplementationofLeanatRheemManufacturing.pptVIP

Implementation of Lean at Rheem Manufacturing Presenter Dr. Joan A. Burtner Associate Professor Industrial and Systems Engineering Mercer University School of Engineering Macon, GA Introduction Background on the Evolution of Lean Manufacturing Overview to Lean Principles Highlights of Implementation of Lean Practices at Rheem Manufacturing Co. in Milledgeville, GA Evolution of Lean Manufacturing Total Quality Management Toyota Production System Six Sigma Process Improvement Theory of Constraints Value Stream Mapping Womack and Jones - Lean Thinking Rother and Shook - Learning to See Continuous Improvement Process (with a lean spin) Clarify improvement needs (objectives) Observe operation(s) through your own eyes Identify problems based on observations Resolve problems (kaizen) New ideas become new standard operating procedure Maintain new methods Continuously repeat steps 1 through 6 Wasteful Practices Waiting Transportation Overproduction Processing Inventory Motion Defective Products Lean Metrics (Quantitative) Lead-times Inventory Inventory Turns Work In Process Workable Floor Space Efficiency Cycle Time Introduction to the 5S’s Typical Improvement Projects Time studies Line Balances Creating work cells Housekeeping (5 S’s) Visual Control General Guidelines for Visual Control at Rheem Work instructions (S.O.P.’S) Quality instructions Safety reminders Clearly marked part delivery locations Tool boards (where needed) Production boards (where needed) Layouts Implementation of Visual Control at Rheem Spring and Summer 2003 Kaizen and 5 S All Assembly Lines Created Zoned Housekeeping Layouts for All Major Production Areas Designated Part Delivery and Storage Locations Placed Production and Quality Status Boards Began Drafting Standard Operating Procedures and Safety Reminders for All Work Stations Kaizen of an Assembly Line 1 Kaizen of an Assembly Line 2 Using Work Teams at Rheem Cross-functional work teams for solving problems Composition of Work Tea