ISE 362 - Lean Production Week 1 IDEAL Systems HOW?

ISE 362 - Lean Production Week 1 IDEAL Systems HOW? İzmir University of Economics Halil POSACI 2013, İzmir

www.halilposaci.com Graduated from METU -1978 MBA Planning & Org. DEU IT Manager Tarişbank -2000 IT Coordinator Smart Ticketing System 2000-2010 Part time instructor in IUE 2003- IT Consultancy training Meta-USA, Germany Solar system design training SMA Germany 2010 Lean Production - Halil POSACI 2

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

About the Course Syllabus http://homes.ieu.edu.tr/hposaci -> ise362 Lean Production - Halil POSACI 4

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

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

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

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

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

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

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. 2008 12 Million capacity = USA Auto industry Lean Production - Halil POSACI 11

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

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

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

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

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

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

Use Of A3 Lean Communication Lean Production - Halil POSACI 18

Use Of A3 Lean Communication Lean Production - Halil POSACI 19

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

5S Lean Production - Halil POSACI 21

1. Seiri - Sort Lean Production - Halil POSACI 22

2. Seiton - Stabilize Lean Production - Halil POSACI 23

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

3. Shine Keep clean Lean Production - Halil POSACI 25

4. Seiketsu - Standardize Lean Production - Halil POSACI 26

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

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

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

Conference http://www.mmo.org.tr/etkinlikler/baharkonferansi/ Gain 5 points for meeting reports you attend. (With your own hand writing) Lean Production - Halil POSACI 30

Conference Lean Production - Halil POSACI 31

Questions HPosaci @ quiztechnology. com 532 2877127 NEXT Lesson: Why Lean? How Lean? & Terminology Lean Production - Halil POSACI 32