Why are Starbucks so successful?
What do they do well?
What do they think makes a
successful business?
• Making money
• Keeping the customer happy
• Good quality product
• Being recognised
HOW DO THEY DO IT?
Lean Manufacturing is about creating the
ultimate factory.
What should the ultimate factory look like?
The ultimate
factory should…
Scenario 1:
1. Fold the paper
2. Stuff the envelope
3. Seal the envelope
4. Stick on the stamp
5. Store them neatly in the box.
5 volunteers!
Each worker must
complete their tasks
in full before the
next starts.
Scenario 2:
1. Fold the paper
2. Stuff the envelope
3. Seal the envelope
4. Stick on the stamp
5. Store them neatly in the box.
5 volunteers!
Each worker
completes 1 task
then passes to the
next.
Scenario 2:
Scenario 2 is faster!
It is lean manufacturing.
It is called Just In Time
What are the benefits of JIT?
•
….
•
….
•
…
What else is Lean?
Less area to walk around
What else is Lean?
No time wasted finding tools.
What else is Lean?
Easy to read ways of tracking jobs.
What else is Lean?
Quick ways to quality check work.
What else is Lean?
Clear description of who should
be doing what.
So, watch this video and answer the question….
What is Lean Manufacturing?
Let’s see how its done for real…
How does a company get Lean?
Method 1: JUST IN TIME
Method 2: KAIZEN
Method 3: POKA - YOKE
Method 1: JUST IN TIME
The production process is organised in a way
that makes sure:
• Parts are available when you need them.
• Equipment is available when you need it.
• Workers only move when they need to.
• Products are build to customer demand.
• There is no stock waiting to be sold.
• Production time is the least time possible.
• Automation is used to speed up manufacturing.
Method 2: KAIZEN
Method 2: KAIZEN
Method 2: KAIZEN
Method 2: KAIZEN
Created in 1930 by Sakichi Toyoda.
Method 2: KAIZEN
Created in 1930 by Sakichi Toyoda.
Method 2: KAIZEN
Created in 1930 by Sakichi Toyoda.
He created a method of improving the factory by
constantly introducing small changes that
improved quality and efficiency.
Kaizen is special because it lets decisions be made by the workers.
Why is that a good way to improve?
Method 2: KAIZEN
Improvements are small changes.
The workers have the ideas so they should be easier to make happen in
the factory.
Small changes don’t cost a lot of money. It is a cheaper way to improve
your factory.
Using the workers encourages them to take more ownership in their
work – this improves MOTIVATION!
Method 3: POKA - YOKE
This method tries to remove HUMAN ERROR!
Method 3: POKA - YOKE
This is a good example of Poka-Yoke.
Method 3: POKA - YOKE
Poka-Yoke aims to mistake proof
the factory.
It looks at simple process in the
factory and comes up with ways of
stopping them from going wrong.
• Improves quality by removing errors.
• Speeds up production by having a higher quality of product. (less mistakes!)
• Increases safety. Less injuries through mistakes.
• Reduces costs by improving efficiency and the skill needed by the workers.