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New Employee Lean Orientation

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How to on-board new hires to get them familiar with lean and speed their contribution to continuous improvement

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The Lean Workplace (New Employee Lean Orientation)
What does Lean mean? 5S VFM 8 Waste Error Proof
Your Workplace ,[object Object],[object Object],[object Object]
Lean is Market Driven ,[object Object],[object Object],We can not afford to stand still, therefore we must continuously improve
S t r a t e g y E x e c u t i o n Who makes it happen Lean Initiatives used to implement and sustain continuous improvement Where process happens Process Actions What are the benefits Who shares the success Why do it Performance Metrics Safety HR Cost Delivery Quality Financial and Social Objectives Workplace Organization Teamwork / Training Visual Factory Management Continuous Improvement Value Stream Mapping Change - Over Error Proofing Pull Systems Total Productive Maintenance Standard Work Your people making products and services for your customers Stakeholders Vision Business Plan Balanced Scorecard Lean Assessment Lean Operating System
Lean Building Blocks Quick Changeover Standardized Work Batch Reduction Teams Quality at Source 5S System Visual Plant Layout POUS Cellular/Flow Pull/Kanban TPM Value Stream Mapping Continuous Improvement Lean Vision Change-Over Pull System Standard Work Teamwork/Training Error-Proofing Visual Factory Management Total Productive Maintenance Continuous Improvement Workplace Organization
Lean Building Blocks --Must Know Initiatives Quick Changeover Standardized Work Batch Reduction Teams Quality at Source 5S System Visual Plant Layout POUS Cellular/Flow Pull/Kanban TPM Value Stream Mapping Continuous Improvement Lean Vision Change-Over Pull System Standard Work Teamwork/Training Error-Proofing Visual Factory Management Total Productive Maintenance Continuous Improvement Workplace Organization
Workplace Organization --where you do your job What Is 5S?? 1S 2S 3S 4S 5S Sort Straighten Shine Standardize Sustain
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],5 S Purpose
[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],A place for everything and everything in it’s place
[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object],[object Object]
5 S - Sustain 3 S Sustain Standardize (Sort, Straighten, Shine)
Lean Vision ,[object Object],Customer Order Waste Product Shipment X
8 Wastes
Eliminate these 8 WASTES ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Defects ,[object Object],[object Object],[object Object],[object Object],[object Object]
Overproduction ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Waiting ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Not Using Talent ,[object Object],[object Object],[object Object],[object Object]
Transportation ,[object Object],[object Object],[object Object]
Inventory ,[object Object],[object Object],[object Object],[object Object],[object Object]
Motion ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Extra Processing ,[object Object],[object Object],[object Object],[object Object]
Visual Factory Management COB @ the Worksite (Daily) PAB @ the workbench (Hourly) Information Center (Plant-wide Reporting) Information From Each Department PPB Within the department (Monthly)
What is Visual Factory Management? ,[object Object]
Visual Factory Management ,[object Object],[object Object],[object Object],[object Object],[object Object]
Process Analysis Board ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Process Analysis Board
Certified Operating Board ,[object Object],[object Object],[object Object]
Certified Operating Board
Process Performance Board ,[object Object],[object Object],[object Object]
Process Performance Board
Information Center ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Control Area
Standard Work ,[object Object],Do the job the same way every time ! I don’t care how I do the job, just get it done !
Standard Work
Error Proofing ,[object Object]
Definition of Error Proofing ,[object Object],[object Object]
Errors vs. Defects ,[object Object],[object Object],[object Object],[object Object],[object Object]
Summary ,[object Object],[object Object],[object Object],[object Object],[object Object]

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New Employee Lean Orientation

  • 1. The Lean Workplace (New Employee Lean Orientation)
  • 2. What does Lean mean? 5S VFM 8 Waste Error Proof
  • 3.
  • 4.
  • 5. S t r a t e g y E x e c u t i o n Who makes it happen Lean Initiatives used to implement and sustain continuous improvement Where process happens Process Actions What are the benefits Who shares the success Why do it Performance Metrics Safety HR Cost Delivery Quality Financial and Social Objectives Workplace Organization Teamwork / Training Visual Factory Management Continuous Improvement Value Stream Mapping Change - Over Error Proofing Pull Systems Total Productive Maintenance Standard Work Your people making products and services for your customers Stakeholders Vision Business Plan Balanced Scorecard Lean Assessment Lean Operating System
  • 6. Lean Building Blocks Quick Changeover Standardized Work Batch Reduction Teams Quality at Source 5S System Visual Plant Layout POUS Cellular/Flow Pull/Kanban TPM Value Stream Mapping Continuous Improvement Lean Vision Change-Over Pull System Standard Work Teamwork/Training Error-Proofing Visual Factory Management Total Productive Maintenance Continuous Improvement Workplace Organization
  • 7. Lean Building Blocks --Must Know Initiatives Quick Changeover Standardized Work Batch Reduction Teams Quality at Source 5S System Visual Plant Layout POUS Cellular/Flow Pull/Kanban TPM Value Stream Mapping Continuous Improvement Lean Vision Change-Over Pull System Standard Work Teamwork/Training Error-Proofing Visual Factory Management Total Productive Maintenance Continuous Improvement Workplace Organization
  • 8. Workplace Organization --where you do your job What Is 5S?? 1S 2S 3S 4S 5S Sort Straighten Shine Standardize Sustain
  • 9.
  • 10.
  • 11.
  • 12.
  • 13.
  • 14. 5 S - Sustain 3 S Sustain Standardize (Sort, Straighten, Shine)
  • 15.
  • 17.
  • 18.
  • 19.
  • 20.
  • 21.
  • 22.
  • 23.
  • 24.
  • 25.
  • 26. Visual Factory Management COB @ the Worksite (Daily) PAB @ the workbench (Hourly) Information Center (Plant-wide Reporting) Information From Each Department PPB Within the department (Monthly)
  • 27.
  • 28.
  • 29.
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