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LEAN PROGRAM
Done by:
Sreekumar Unni
Sooraj Santhosh
Sabari Sreekumar
Umesh
COMPANY PROFILE
PROBLEMS FACED
High inventory levels due to products at the end of life cycle.
Inability to linkup with OEMs for new product introductions.
Inability to plan, forecast demand and control process.
Inefficient capacity planning.
Problems in organization design, manufacturing architecture and
material flow methodologies.
Lack of clarity.
Lack of coordination between shop floor and overall business
objectives.
PROJECT BACKGROUND
Planned to implement lean management through a series of
kaizen events.
Backed up by 4-day lean class to enhance knowledge transfer.
Program was extended to cover entire business operations.
Target 23 companies
Time frame:- April Dec 1999
Primary Scope & Objective:
At least one Kaizen event @ 23 companies.
Expose as many employees as possible to the 4-day lean class.
PROJECT APPROACH
Team- Cross functional teams of 8 to 12 people.
Each team had a leader.
First Day-totally of training and education on multiple lean
manufacturing topics (e.g., one-piece flow, Kanban, visual management,
measures, etc.).
Second and Third daysBaselined the existing process.
Designed a new process.
Demonstrated the new process, including the rearrangement of equipment.
Re-baselined the new process.
TIMELINE
BENEFITS ACHIEVED
TECHNIQUES UTILIZED
Lean Manufacturing ( Kaizen
Event)
One-piece flow
Takt time
Kanbans
Material pull,
5S housekeeping
Visual controls
Process mapping
SMED
TPM
Poka-yoke etc
Jidoka
Autonomation
Andon
visual controls
Just-in-time
Takt time
Continuous flow
Pull systems
5S housekeeping
Muda
Process mapping
Kanban,
Poka-yoke
TPM etc