Lean Six Sigma Introduction

Large Lot Sizes - Their Origin and Effect

Problems

Setup times are long
There are quality and maintenance issues

Solutions

Run large batches to gain high efficiencies, to lower standard costs, or to provide a buffer against problems.

Results

Production flow is lumpy and schedules don’t match assembly (or customer) needs

Effect

Inventory and WIP get big. Deliveries suffer.

So

High inventory carrying costs. Problems are masked. trail is cold

Road Map for Implementing Lean Manufacturing

1. Identify a product family (with similar routings) to start with and an area to begin in, usually at or near final assembly
2. Determine daily demand rate for each item 
3. Identify processes for common items to be included in lean cell/line
4. Calculate takt times for each process
5. Define the standard work content 
6. Calculate amount of resources for each process
7. Determine cell/flow line general layout
8. Balance the workflow
9. Calculate the number of kanban containers (the amount of WIP) 
10. Follow the Steps for Implementing a Lean Project (Implementation Level 3) 
11. Begin to use pull signals to draw material from the feeder operations and outside suppliers, but continue to use inventory as a buffer until they can respond to the pull signals 
12. Develop Lean capabilities, following the Steps for Implementing a Lean Project, for the next upstream feeder operation  
13. Follow step 11 for this feeder operation  
14. Repeat steps 12 and 13, cascading up the supply chain, for the next upstream operation, and for the key suppliers

Copyright © 2000-2010 Michael G. White. All rights reserved.