Collect some examples from the group members about their experiences with Lean and Six Sigma 15 minutes 4) Reconvene and present your work to the rest of the class QUAL50172 mod2-wk2-2016
Lean Six Sigma Taiichi Ohno QUAL50172 mod2-wk2-2016 9 Image Source: • “Ohno decided there was no reason other than inefficiency and wastefulness why Toyota's productivity should be any lower than that of Detroit. • “Hence he set out to eradicate inefficiency and eliminate waste in the part of the production process that he was responsible for. • “This became the core of the so-called Toyota Production System (TPS) that he and others subsequently developed between the mid-1940s and the mid- 1970s. • “Several elements of this system have become familiar in the West: for example, muda (the elimination of waste), jidoka (the injection of quality) and kanban (the tags used as part of a system of just-in- time stock control).” Source: http :// 2009 Japanese Industrial Engineer and Businessman Known as the “Father of The Toyota Production System” Born: 1912 Died: 1990
Lean Six Sigma 7 Wastes The Seven “ Muda ” (Japanese word for any activity that consumes resources but adds no value; also known as “ waste ”) – According to Taiichi Ohno’s enumeration of the types of waste commonly found in physical production of tasks and conversion of activity into services 1) . Overproducing ahead of demand 2) . Waiting for the next process step 3) Unnecessary transport of materials [and information] 4) . Over-processing parts due to poor tool and product design [extra and over processing documents and approvals] 5) . Inventories [of parts, data, information, people, electrons, cash] more than the absolute minimum 6) . Unnecessary movement of people [parts, data, information, electrons, cash], during the course of work or processing (looking for things, help, etc.) 7) Production of parts and services with defects 10 QUAL50172 mod2-wk2-2016 10
Lean Six Sigma The 8 th Waste Not Fully Utilizing your People : (The Greatest Waste of All) A) Under-Utilizing: • Not applying and harvesting the full capabilities of your employees • Training but not using the capabilities learned • Expecting high-performance from untrained or inadequately trained people B) Over utilizing and over-relying on a few employees • Over relying on a select few • High overtime\Incessantly increasing time demands • Unsteady flow and non-level loaded work- hurry-up and wait Some causes of the 8 th Waste: •
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- Winter '19