After identifying the value stream for a product, the focus is on avoiding batch and queue between different steps in the process flow.
You must ensure that the next downstream operation has:

• only what is needed
• just when it is needed
• in the exact amount needed

Enabling flow without interruption, detours, backflows, waiting and scrap presents a constant challenge.
General, the batch size should be reduced to the smallest possible size.
The end target is to enable single or one piece flow, meaning producing only one product at a time.

You can learn more about one piece flow and lean manufacturing at http://www.LeanManufacturingCoaching.com

Availability

• % of scheduled time that equipment is available to produce products
• causes of lower availability: equipment failure, breakdowns, setup, adjustments

Performance

• actual rate of production as a % of design or ideal rate
• causes of lower performance: minor stopping, idling, reduced speed

Quality

• % of good products out of the total products produced
• causes of lower quality: process errors, rework, scrap

More information about OEE and Overall Equipment Effectiveness 
 

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Weekly Subjects

5S Introduction
5S Seiri
5S Seiton
5S Seiso
5S Seiketsu
5S Shitsuke
Processes and Equipment
Business Process Fundamentals
Process Flowcharts
Process Mapping
Introduction to Statistical Process Control
Process Control Charts
Process Capability
Process Capability and Six Sigma
Equipment - Six Big Losses
OEE (Overall Equipment Effectiveness)
Maintenance Management Principles
Standardized Work
Value-added and non-value-added work.
Overproduction
Excess Transportation
Excess Inventory
Excess Processing
Waiting
Correction and Rework
Motion waste
Lean Six Sigma
Value Stream Mapping
Current State Mapping
From Current State Map to Future State Map
Takt Time.
Continuous Flow
Operator Balance Chart
Pull Manufacturing
Pull Manufacturing Control Methods
Visual Factory Management
Poka Yoke or Error Proofing
SMED or Quick ChangeOver
TPM - Autonomous Maintenance
Kaizen - Continuous Improvement - Kaizen Blitz
The Lean Supply Chain
Supply Chain and Value Stream Mapping
Lean Procurement
Lean Warehousing
Lean Transportation
ABC Classification and Pareto Diagram
TPM and RCM
CMMS (Computerized Maintenance Management System)
Six Sigma Introduction
Six Sigma Methodology 1
Six Sigma Methodology 2 - Measure
Six Sigma Methodology 3 - Analyze
Six Sigma Methodology 4 - Improve
Six Sigma Methodology 5 - Control.
Lead Time and Lead Time Reduction.
Lead Time and Lead Time Reduction.
Lead Time Reduction - Order Capturing.
Lead Time Reduction Tip - Know your Customer.
Office Value Stream Mapping and Office Wastes.
Office Waste Reduction and Elimination (1).
Office Waste Reduction and Elimination (2).
Paperless Electronic Document Transfer.
Order Planning and Scheduling.
Demand Planning.
Free Project Management Guide Ebook.
Production Planning and APS.
Pareto Chart Software.
The Distribution Activity.
Lean Manufacturing Implementation Roadmap.
ManagementSupport: Free TPM Presentation (38 slides)
ManagementSupport: Reports for Managers.

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Elements of visual management are

• visual displays: relate information and data to employees in the area. Examples are charts, procedures, metrics and process documentation
• visual controls: intended to control the actions of the group members. Examples are status boards and quality controls
• visual process indicators: examples are painted flow areas and flow indicators
• visual documentation of processes

Click Here to access The Lean Manufacturing Coaching Program

Assess your company

• define product groupings and current processes
• specify value
• identify the value stream (current and future state map)

Educate at all levels

Support the learning of the lean tools and methods

Implement the lean tools and methods

• organize the workplace (5S)
• improve plant layout for flow manufacturing
• reduce lot sizes, setup times, lead times and inventory
• develop a pull system
• standardize operations
• improve quality
• improve maintenance

Modify the organization structure: everybody’s job is going to change, people from the shop floor to the top floor will work differently and in departments that are structured differently

Establish improvement metrics

Seek perfection

Click Here to access The Lean Manufacturing Coaching Program.

CMMS Definition

Computerized Maintenance Management System: computer replaces manual systems

Basic Modules

• Asset register
  • documentation
  • equipment data management
  • multi-level hierarchical filing system
• Work order management
• History file
  • required for feedback
  • maintenance of work preparations
  • reporting
• Spare parts inventory control

Optional modules

• Budget analysis
• Invoice / ordering control
• Condition Based Maintenance Manager
• Failure analysis

Trends

• Internet-enabled
  • bringing information and training to the shop floor
  • transferring analysis data to equipment suppliers
  • online equipment monitoring
  • purchasing of spare parts (e-procurement)
  • software vendors will host CMMS on their own servers (Application Service Providers)
• Data Input:
  • Use of handheld computers by technicians
  • Interfacing with bar code terminals
• Integration of Supply Chain Software and CMMS

Click Here to access a Powerpoint Presentation about Maintenance Management (78 slides).

Value Stream
The value stream is an end-to-end collection of processes that create value for the customer.
The value stream includes
- people
- tools and technologies
- physical facilities
- communication channels
- policies and procedures

Value Stream Mapping
Value Stream Mapping is a method to describe the flow of material and information through the production system.
By graphically portraying the process, one is able to see where value is added and value is lost.
The ratio of value added to total lead time is figured by documenting the current lead time, inventory levels and cycle times.
The visual representation allows to see where costs can be reduced and improvements can be made.
A future state can be designed where wasted steps are left out, and continuous flow and pull production are introduced.

Click Here to access 2 Value Stream Mapping Presentations (84 slides).

Maintenance: Any activity carried out on an asset in order to
- ensure that the asset continues to perform its intended functions
- repair the asset

Reliability Centered Maintenance (RCM): a methodology used to determine the right maintenance tasks, to ensure that any physical asset or system continues whatever its users want it to do, in its present operating context.

Click Here to access an RCM Powerpoint Presentation (54 slides).

• You can evaluate your suppliers or vendors online
• There are 20 supplier evaluation criteria
• You can give a weight to each of the supplier criteria
• You can give a score for each of the supplier criteria
• A total score will be calculated, and the result of the supplier evaluation can be printed out
• This tool will help you with your supplier or vendor selection

Get access to the Online Supplier Evaluation Tool