ISE Lean Production Week 1 IDEAL Systems HOW?

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1 ISE Lean Production Week 1 IDEAL Systems HOW? İzmir University of Economics Halil POSACI 2013, İzmir

2 Graduated from METU MBA Planning & Org. DEU IT Manager Tarişbank IT Coordinator Smart Ticketing System Part time instructor in IUE IT Consultancy training Meta-USA, Germany Solar system design training SMA Germany 2010 Lean Production - Halil POSACI 2

3 Agenda About the course Ideal System design (Can it be real) What is a system? Design - Implement - Control Huge steps in the history From Taylor to TPS What is (Being) Lean? Developing Strategy VSM A3 5S Lean Production - Halil POSACI 3

4 About the Course Syllabus -> ise362 Lean Production - Halil POSACI 4

5 What is A System System Manufacturing Systems Goods Services Black Box Vision Strategy Targets System Lean Production - Halil POSACI 5

6 IDEAL System - Can It Be Real AVAILABLE SYSTEM Some Cost Some Production Some Service Zero Cost IDEAL SYSTEM Infinite Production Infinite customer satisfaction Lean Production - Halil POSACI 6

7 Stakeholders Stakeholders Vision Strategy Targets System Lean Production - Halil POSACI 7

8 Design Implement - Control Design DESIGN IMPLEMENT CONTROL Use it Control it Improve it Up to ideal It is an endless and hard process FEEDBACK Lean Production - Halil POSACI 8

9 Huge Steps In The History Line Automation Taylor Gilberth Ford 1908 Model T Production line YouTube Easy to produce Easy to repair Mass production > Hours to Minutes Lean Production - Halil POSACI 9

10 Mass Production Huge Steps in History Growing Dysfunction» Worker alienation» Quality problems» Huge machinery -> in process inventory» Too many details for ENGINEERS to handle Pressure of unions Lean Production - Halil POSACI 10

11 Huge Steps in History BPR (A continuous process) 1937 Toyota had been founded by Toyoda family 1950 Eiji Toyoda visited Ford Rouge plant Which produce 7,000 vehicles/day.» Toyota had capacity of 2600,» Market was small and demanding for different models,» Japan economy was torn by war (Capital problems) Life time employment Pay steeply graded by ranks and depends on profitability Million capacity = USA Auto industry Lean Production - Halil POSACI 11

12 What Is (Being) LEAN? Do not spend for more than customer needs Leaner Process can run on less equipment less materials less time less space less human effort Lean Production - Halil POSACI 12

13 What Is (Being) LEAN? Competitors and Customers decide about the price Old Equation: Cost + Profit = Price New Equation: Price (fixed) Cost = Profit Lean Production - Halil POSACI 13

14 What Is (Being) LEAN? Eliminate Wastes Lean Production - Halil POSACI 14

15 Hoshin Kanri Developing Strategy Listen to Customer DEVELOP STRATEGY BASIC MANAGEMENT Planning- Organizing Leading - Control Lean Production - Halil POSACI 15

16 Value Stream mapping Understanding Your System Lean Production - Halil POSACI 16

17 Value Stream Mapping Value Stream Re-understand your system as cells Work Analysis Macro Micro Lean Production - Halil POSACI 17

18 Use Of A3 Lean Communication Lean Production - Halil POSACI 18

19 Use Of A3 Lean Communication Lean Production - Halil POSACI 19

20 5S Seiri Sort, eliminate waste Seiton Stabilize, arrange locations & fix Seiso Shine, clean out the work space Seiketsu Standardize the methods Shitsuke Self discipline and motivation Lean Production - Halil POSACI 20

21 5S Lean Production - Halil POSACI 21

22 1. Seiri - Sort Lean Production - Halil POSACI 22

23 2. Seiton - Stabilize Lean Production - Halil POSACI 23

24 2. Seiton Stabilize 3. Shine Keep clean Everything in a fixed place, And Clean Lean Production - Halil POSACI 24

25 3. Shine Keep clean Lean Production - Halil POSACI 25

26 4. Seiketsu - Standardize Lean Production - Halil POSACI 26

27 5. Shitsuke - Sustain Keep It Working Keep motivated Lean Production - Halil POSACI 27

28 What has covered? Ideal System design (Can it be real) What is a system? Design - Implement - Control Huge steps in the history From Taylor to TPS What is (Being) Lean? Developing Strategy VSM A3 5S Lean Production - Halil POSACI 28

29 Resources? All Available as e-book Lean Production - Halil POSACI 29

30 Conference Gain 5 points for meeting reports you attend. (With your own hand writing) Lean Production - Halil POSACI 30

31 Conference Lean Production - Halil POSACI 31

32 Questions quiztechnology. com NEXT Lesson: Why Lean? How Lean? & Terminology Lean Production - Halil POSACI 32