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LSS&BE – 19MO42 / 19PO42

S. Krishna Kumar(KK)
IV Trimester - July ‘20 – Oct ‘20 – Session 13 – 19th Aug’20
Welcome to Class – th Aug’

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Recap of Class on Aug’
(Pl use chat window )

1. What is PQCDSM
2. What are the various categories in lean
audit check list

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BIQ & The Lean Operating System

Knowledge
Sharing
• Integrated System
Std Starts 5S
designed to drive
sustainable Customer Data
and Internal Quality and Collection
and
TPM Retrieval Escalation
Delivery improvements Skill
Matrix 6M
Change
and
Mngement
Training

• Daily accountability
through standard work Std Tiered
and structured tiered Work BIQ Meetings
Mistake 6 Sigma
meetings to ensure Proofing (PCPX)

alignment and focus


Leadership Waste
Std Work Standard ID
BIQ – Built in Quality QMB
Starts

QMB – Quality Management Board


Process Visual
Flow Management
RPS – Rapid Problem Solving RPS
Lean Material Control
Inventory Forecasting : The number of items stocked ,
type of items, lead time, and turnover ratio. Collect all the
historical data in one place to analyze and interpret.
Vendor Managed Inventory (VMI) : Vendor reviews the
inventory, stocks it, and places any order for
replenishment as needed. You can avoid over-stocking
and billing based on consumption
Stakeholder Alignment : A healthy collaboration
between Vendors , employees and customers can help
resulting in better turnover ratio

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Lean Purchasing principles
Buying only when necessary
Having more than on source
Compare the landed costs inside the works
Introduce Kanban system with your vendors
Supplier quality assurance
Constant interface with Sales & Marketing
Keep an eye on product obsolescence & technology
upgradation
Group purchasing if there are different organisations
within the group for same materials

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Lean organisation & Roles
Shift the focus from existing organisation , technology
, processes and assets to the customer and product
Differentiate value from waste
Enhance value and remove waste along the value chain
Every role in the organisation should add value to the
product or in the eyes of the customer
Share staff functions for ex – HR , Accounts ,
Administration across group companies
From job description , evaluate the hours of work
necessary. The roles can be combined to an employee.

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Economics of Lean Manufacturing
Maximum utilization of Man - skilled and/or unskilled
Optimal module size - cellular and/or plant
Smooth traffic flow - of materials, man, automotive
Minimum total manufacturing cost - of products
produced
Reduce investment
Reduce labor requirement
Utilization of more productive equipment and
disposition of less productive equipment
Flexibility to be contemporary / keep pace with market
/ customer changes
Increase Return On Net Asset

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Steps of Lean Transformation

##

## - Identify the various activities as VA / NVA / RNVA . NVA should go out


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Sustaining Lean culture
Create a continuous improvement culture
Learning from errors and mistakes
Multiskilling through periodic interventions for
versatility and career progressions
Individual development plan for each employee
Promote action and learning at the Gemba
Long term goals vs short term goals and the connect
Constant interactions with the Head of business and the
operating team to quickly factor changes and move on
A culture of transparency and openness in dealings. Also
fairness in evaluation and rewards.

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Business Model Canvas ( from lean)

Link : https://upload.wikimedia.org/wikipedia/commons/1/10/Business_Model_Canvas.png
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Plan for next Class ( 20 th Aug’20)
1. 4.15 – 4.20 – Quick recap / settling down
2. 4.20 – 4.35 – Quiz 2 ( similar to quiz 1)
3. 4.40 - 5.25 – Project discussions @ 5 min / team.
Only one person will present as per format for max of
2 min. Balance 3 minutes are for deliberations
4. 5.25 – 5.30 – Feedback on project progress by Prof .
Patel
5. 5.30 – 5.35 – Spill over / freewheeling.

## - Prof Patel will be joining us for the review and


evaluation.
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Checks for Understanding
(Today’s class ) – Chat Box
1. Lean material Control
2. Lean Purchasing
3. Economics of lean culture
4. Steps of Lean Transformation
5. Sustaining lean culture
6. Any doubts in Lean Mfg

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PROJECT

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Thank You.

See you in the next class


th
– 20 Aug ‘ 20

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