By Jon Miller | Post Date: October 21, 2008 11:56 PM | Comments: 0
Another way to think about lean manufacturing is that it is a system of stopping: no more waste, variation or overburden, just the value the customer wants at the right speed, quality and cost. The classic TPS house comprised of the pillars of JIT and jidoka (built in quality + autonomation) on the foundation of heijunka (production smoothing) with cornerstones of standard work (takt, work sequence, standard WIP) and kaizen (continuous improvement). In the lean management system there are various supporting philosophies, tools, systems and subsystems to enable high performance across all metrics by following this model. These are all in fact ways of stopping behaviors that detract from high performance. Here is the TPS house as a system of stopping:
Stop making the same thing. The foundation of the TPS house is heijunka or production smoothing, which is to produce every needed product every cycle (daily). This is done by reducing changeover times, working with the production planning, sales and customer organizations to break orders from large quantities into smaller ones that more closely reflect the actual consumption, thereby reducing the bull whip effect not only within the site but across the supply chain.
Stop if you can't follow the standard. The jidoka pillar, whether auto-stop built in as autonomation / intelligent automation into machines or the manual andon lamp and cord used to call for help, are ways of allowing the process to alert the area supervision to potential problems early and often. This is no to say simplistically "stop the line" but rather create a system that proactively seeks out minor problems during the course of work before they become line-stoppers. This requires first stabilizing endemic issues and assigning the resources needed at the line to address sporadic stoppages.
Thank you for reading. But now please stop reading and go help someone make things better.Comments are moderated to filter spam and inappropriate content. There may be a delay before your comment is published.