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Where does the Lean Manufacturing philosophy / tool set come from?
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Where does the Lean Manufacturing philosophy / tool set come from?
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  Post Number #1  
Old 23rd April 2007, 02:20 PM
andrewg

 
 
Total Posts: 89
Please Help! Where does the Lean Manufacturing philosophy / tool set come from?

Help Please?

I am a new quality auditor and have spent the past few years learning that role. My organisation is starting a 'lean programme' and I have to confess to knowing very little about it. Could someone please provide some basic background knowledge on this tool? Where does it come from? What it is used for? How it operates? When auditing this function, what to look for?

Your advice and knowledge are very welcome.

Thank you and Regards,

Andy

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  Post Number #2  
Old 23rd April 2007, 02:53 PM
gszekely

 
 
Total Posts: 205
Re: Where does Lean come from?

Hello Andy !
Answers for some of your questions you may find by rolling down to the bottom of this page and reading similar threads.
You can do a search on forum, and check post attachment list for presentations.
You can run a google search, for ppt files.
And take a look here:
http://www.lean.org/
http://www.strategosinc.com/resources.htm
and also here some basic assesment tool:
http://www.strategosinc.com/assessment.htm

BR
György
Thank You to gszekely for your informative Post and/or Attachment!
  Post Number #3  
Old 23rd April 2007, 02:54 PM
Claes Gefvenberg's Avatar
Claes Gefvenberg

 
 
Total Posts: 4,952
Lightbulb Re: Where does Lean come from?

Quote:
In Reply to Parent Post by andrewg View Post

Help Please?

I am a new quality auditor and have spent the past few years learning that role. My organisation is starting a 'lean programme' and I have to confess to knowing very little about it.
In that case I suggest a look at the Lean Manufacturing history, and of course the Cove wiki about lean Manufacturing.

/Claes
Thank You to Claes Gefvenberg for your informative Post and/or Attachment!
  Post Number #4  
Old 23rd April 2007, 03:09 PM
Pazuzu - 2009

 
 
Total Posts: 150
Re: Where does Lean come from?

Quote:
In Reply to Parent Post by andrewg View Post

Help Please?

I am a new quality auditor and have spent the past few years learning that role. My organisation is starting a 'lean programme' and I have to confess to knowing very little about it. Could someone please provide some basic background knowledge on this tool? Where does it come from? What it is used for? How it operates? When auditing this function, what to look for?

Your advice and knowledge are very welcome.

Thank you and Regards,

Andy
In a nutshell...it's trimming the waste from your processes to leave behind the value-added events that the customer is 'willing' to pay for. Think of a T-Bone steak from your grocery store. Say you spend $15 on the T-bone (and keep in mind that meat is sold by weight). 1/2 the weight is bone, and a bit more is the fat surrounding the meat. The bone and fat (no value) is waste yet you're buying it because it's part of the package with the meat (value). $15 for $6 of meat is not customer friendly. Learning how to identify the bone and fat, eliminating it from your process, and then concentrating on the meat is more efficient for you and is what the customer is willing to pay for.
Thank You to Pazuzu - 2009 for your informative Post and/or Attachment!
  Post Number #5  
Old 23rd April 2007, 06:27 PM
DAB68

 
 
Total Posts: 28
Re: Where does Lean come from?

Quote:
In Reply to Parent Post by andrewg View Post

Help Please?

I am a new quality auditor and have spent the past few years learning that role. My organisation is starting a 'lean programme' and I have to confess to knowing very little about it. Could someone please provide some basic background knowledge on this tool? Where does it come from? What it is used for? How it operates? When auditing this function, what to look for?

Your advice and knowledge are very welcome.

Thank you and Regards,

Andy
Henry Ford. Toyota took Ford's concepts and improved them. Study the Toyota Production System and you'll learn lean. Just understand, it is NOT a tool. It is a business strategy and a corporate culture. For your company to be truly lean, lean must be lived at all levels of the organization.
Thank You to DAB68 for your informative Post and/or Attachment!
  Post Number #6  
Old 23rd April 2007, 09:57 PM
Wes Bucey's Avatar
Wes Bucey

 
 
Total Posts: 11,159
Re: Where does Lean come from?

Quote:
In Reply to Parent Post by Pazuzu View Post

In a nutshell...it's trimming the waste from your processes to leave behind the value-added events that the customer is 'willing' to pay for. Think of a T-Bone steak from your grocery store. Say you spend $15 on the T-bone (and keep in mind that meat is sold by weight). 1/2 the weight is bone, and a bit more is the fat surrounding the meat. The bone and fat (no value) is waste yet you're buying it because it's part of the package with the meat (value). $15 for $6 of meat is not customer friendly. Learning how to identify the bone and fat, eliminating it from your process, and then concentrating on the meat is more efficient for you and is what the customer is willing to pay for.
Pretty good analogy.

I might also add American Society for Quality (ASQ) has a Division devoted to Lean. The members of that Division are currently working on creating a Body of Knowledge (BOK) about Lean.

A BOK is a listing of the facts, history, and techniques that a competent practictioner should have in his "toolkit" for working in a particular field. An ASQ BOK also include resources for acquiring that knowledge. Eventually, the Division will create a "competency test" for Lean resulting in formal certification for those who pass the test.

Readmore about BOK and Certification at ASQ's website about the revision underway for the BOK of Six Sigma http://www.asq.org/certification/six-sigma/prepare.html

Check out the work in progress of the very new Lean Division (less than one year old!) at http://www.asq.org/le/
Thank You to Wes Bucey for your informative Post and/or Attachment!
  Post Number #7  
Old 24th April 2007, 03:26 PM
Steve Prevette's Avatar
Steve Prevette

 
 
Total Posts: 2,513
Re: Where does Lean come from?

Quote:
In Reply to Parent Post by Pazuzu View Post

In a nutshell...it's trimming the waste from your processes to leave behind the value-added events that the customer is 'willing' to pay for. Think of a T-Bone steak from your grocery store. Say you spend $15 on the T-bone (and keep in mind that meat is sold by weight). 1/2 the weight is bone, and a bit more is the fat surrounding the meat. The bone and fat (no value) is waste yet you're buying it because it's part of the package with the meat (value). $15 for $6 of meat is not customer friendly. Learning how to identify the bone and fat, eliminating it from your process, and then concentrating on the meat is more efficient for you and is what the customer is willing to pay for.
One difficulty of this analogy (which can be the source of frustration with lean when misapplied) is that if this was really a case in a butcher shop, the butcher would likely end up charging more than the original $15 for the resulting trimmed meat! There is no such thing as a cow without bone or fat. So the butcher is going to have the same cost for the raw material, plus they must now pay for labor to trim the fat and bone. The butcher isn't going to take a loss on this, so they will probably charge the original $15 plus labor. So, the price per pound will more than double.
  Post Number #8  
Old 24th April 2007, 03:55 PM
Pazuzu - 2009

 
 
Total Posts: 150
Re: Where does the Lean Manufacturing philosophy / tool set come from?

Steve...thank you for the insight but I was merely illustrating the basic concept for the originator of this thread who is, by his own admission, new to the lean practice. The bulk of us do understand that there are much more complex underlying dynamics to lean, labour, profit, fixed and variable costs, etc...I just wanted to put it into plain English by using a clearly understandable depiction with hypothetical figures.
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