What does the customer really really want – defines value
Define Waste – 8 ways – all equally important:
- Overproduction
- Waiting (time on hand)
- Unnecessary transport
- Over processing / Incorrect processing
- Excess inventory
- Unnecessary movement in the process of completing the work
- Defects in manufacture – repair / rework costs
- Unused employee creativity
Principles:
- Long term philosophy vs short term goals (Mission – contribute to country economy, well being of stakeholders, and Toyotas growth)
- With the right process the results will follow – trust it
- Continuous process flow to bring problems to the surface (link operations together)
- Use pull systems to avoid over production
- Level out work load (production control and management people) - heijunka
- Culture of stopping to fix problems to get quality right the first time -Judoka ( and Quality – Jidoka)
- Standardise tasks are the basis for continuous improvement and employee empowerment – balance rigid procedures vs challenge to improve
- Visual control so problems not hidden – Just in time information
- Use only reliable tested technology
- Grow leaders who understand the philosophy
- Develop exceptional people that will follow the philosophy
- Learn by doing
- Go and see for yourself (GENCHI GENBUTSU -)
- Make decisions slowly by consensus - Implement Rapidly - Nemawashi – a technique is employed to reduce misunderstanding
- Become a learning organisation through relentless reflection (Hansei) and continuous improvement (CI can only work with stable and standardised processes) –and KAIZEN
Flow
- ID customer and added value
- Separate repetitive from unique processes
- Map flow – value add and no value add
- Future state value stream map
- Learn by doing (Plan do act)
Personal Leanings
- Balance standardisation with individual autonomy – Currently more standardization would create greater efficiency and quality.
- Standardisation is a Core and Key base for CI – without it there is no CI
- Take the time get it right
- How to principles become common?
Web links:
http://www.fredharriman.com/services/glossary/jidoka.html
http://www.strategosinc.com/jidoka.htm
http://www.thinkingmanagers.com/management/gemba.php
http://en.wikipedia.org/wiki/Nemawashi
http://www.si.umich.edu/
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