Lean Manufacturing Implementation

O

orrinxu

#1
I am a recent university graduate and at my current work place i have been tasked with implement a TQM/Lean Manufacturing system to improve turnaround times, quality, decrease wastes/buffers and most importantly improve profits.

Previously I studied Lean and the various tools at college, but honestly I have no idea where to start.

Currently we import a certain portion of our portfolio from China and we are having considerable problems in terms of quality.

Locally, products built by my company quality is very good but there is much waste involved. In particular, one employee in particular constantly holds up production because he is "too busy".

Normally I would advise my boss to remove the problem however this person's skillset is quite unique and I would like to develop a solution that will force this person onto deadlines.

Ideally I would like to develop a Quality Manufacturing system that can not only respond to our local issues, but also with our foreign manufacturers as well and still be able to have excellent turnaround times.

Sorry about the post but I have only learnt these things in theory and I am struggling to work out where to begin to develop this for my company.

EDIT: We are currently ISO 9001:2008 and ISO 14001 accredited
 
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V

viggen

#3
Hello.
You have to start with the top management to get their full backing. Lean is a mindset and "way of living" - the tools are something that has to come in second hand. When you have the mandate you have to find out where to start. I think that you could start with a 5s event in the area where the "to busy guy" is working. To structure up and get rid of anything that don't belong in the area. If you could win this guy over it will be a good start. And you also need to train all the employees in lean thinking. Lean is all about continouos improvement in small steps. And it is not a thing you can do by yourself - you need to get everybody involved.

A tips: Google for "Lean implementation PPT" - you will have over a million hits :)

Best regard - and good Luck
Vegard
 

DanteCaspian

Quite Involved in Discussions
#4
I would be willing to have a simple chat with you on this next via telephone next week. PM me if you would like to set a date and time.
 

Jen Kirley

Quality and Auditing Expert
Staff member
Admin
#5
Welcome to the Cove orrinxu! :bigwave:

One of the great Japanese quality gurus (I think it was Taguchi) said about 80% of problems can be resolved with the 7 basic quality tools.

I can't say for sure that he was correct, but I can say that we very often make problem solving and evaluating effectiveness much more difficult than it needs to be. My best advice to you would be to start with these direct approaches to dealing with issues, especially while you are familiarizing yourself with your systems and surroundings there.

I hope this helps!
 

kgott

Quite Involved in Discussions
#6
I am a recent university graduate and at my current work place i have been tasked with implement a TQM/Lean Manufacturing system to improve turnaround times, quality, decrease wastes/buffers and most importantly improve profits.

Previously I studied Lean and the various tools at college, but honestly I have no idea where to start.

Currently we import a certain portion of our portfolio from China and we are having considerable problems in terms of quality.

Locally, products built by my company quality is very good but there is much waste involved. In particular, one employee in particular constantly holds up production because he is "too busy".

Normally I would advise my boss to remove the problem however this person's skillset is quite unique and I would like to develop a solution that will force this person onto deadlines.

Ideally I would like to develop a Quality Manufacturing system that can not only respond to our local issues, but also with our foreign manufacturers as well and still be able to have excellent turnaround times.

Sorry about the post but I have only learnt these things in theory and I am struggling to work out where to begin to develop this for my company.

EDIT: We are currently ISO 9001:2008 and ISO 14001 accredited

There are also some threads on this forum about what to do in the first weeks of starting a job. I'm sure you'll find it useful to read these as well.
 
K

KathySmith

#7
New to this? Your task will be insurmountable if you don't pick one simple item to focus your work. You already listed a good one for a newbie: SCRAP! Leave the people problems such as that one bad operator to the supervisors and you focus on "systems" or you will surely lose progress. Be careful to already blame others before you even begin your real work? It must be “Yes WE can do this… Yes it can be done!” Operators will soon figure out that you blame them and they will stop working with you. Without the help of the operators that know more about the daily processes, your initiatives will not have a chance... Unless you think you can work 120 hours per week. Systems must be designed so the standard operator will succeed. Think of yourself as new young assistant offensive coach of a pro-basketball team. Your job is to design and write game plays that score points. The head coach worries about the players. Good Luck!
 

sulkinsf

Involved In Discussions
#8
Locally, products built by my company quality is very good but there is much waste involved. In particular, one employee in particular constantly holds up production because he is "too busy".

Normally I would advise my boss to remove the problem however this person's skillset is quite unique and I would like to develop a solution that will force this person onto deadlines.
Hi Orrinxu,

If revenue is limited by production capacity, then your above comment appears to suggest that the "person holding up production" is the bottleneck. You can google "Goldratt's five focusing steps," or refer to others posts on the cove to see where to start.

If your production capacity is not full, then focus on the item that elevates the market demand for your product (e.g. defect reduction).


Best of luck, Steve
 
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