Flextronics Kaizen Practices Drive Improvements for the Customer

Flextronics Paderborn Germany site has mapped its value streams and continually implements improvements using Kaizen techniques. These improvements accelerate the efficiency of the operations over time, as individual changes may be hard to notice, but cumulative effects are signficant. ...

... "We are using the Kaizen cards to record and implement improvements to our workspace. Even changes that seem little at first can have a major impact on the quality and speed of our production. " ...

Via evertiq: Flextronics Lean




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Healthcare Lean Production System

Lean Medical Center Construction

Construction team uses lean in its processes to remove waste and improve cycle times. ...

... "To achieve those goals, the team is utilizing various combinations of lean design and construction project management methodologies enabled by emerging 3D virtual design and assembly technologies to plan, design, coordinate, detail, fabricate, and pre-assemble the various facility components. Notable among those is Value Stream Mapping which enables the team to visually represent their workflow processes and continuously look for opportunities to streamline them to deliver value faster, better, and less expensively. " ...

Via FIATECH: Innovators in Capital Projects

Lean Workflow Automation

University of Wisconsin-Eau Claire implements software to improve its document workflow. ...

... "The university expects to begin deploying its initial group of forms based on the new software in early May, as it concurrently evaluates Lean manufacturing and the value stream mapping process. " ...

Via Campus Technology: Document Workflow Automation

Cardinal Health Lean Value Stream

Cardinal Health introduces new products and services that will improve patient safety and operational efficiency in hospital operating rooms, including lean six sigma consulting services for customers. ...

... "The new Value Stream Mapping service uses Lean Six Sigma methodology to help guide hospitals toward increased efficiency by identifying bottle necks within their current processes, material and information flows. Through collaborative communication and systematic evaluation, hospitals can visualize and analyze areas with costly waste and delays, and create blueprints for process improvements using additional Lean Six Sigma tools and techniques. Cardinal Health helps facilitate these process improvements leading to reduced costs, streamlined workflows, diminished cycle times, increased revenue streams and improved patient and employee satisfaction. " ...

Via Cardinal Health: The Operating Room

Lean Value Stream Mapping Software

Cost of Quality Moves Up the Value Stream

Expect manufacturers to put pressure on their suppliers to eliminate defects throughout the value stream in order to achieve Six Sigma quality levels. ...

... "Manufacturers applying Six Sigma and Lean are eager to remove waste completely from their value streams, which includes avoiding the production of defective materials in the first place, states John Fishell, director of product management ... " ...

Via Purchasing: Quality

Lean Value Stream in ERP System

QAD supports lean value stream ...

Lean Process Mobility for the Shop-Floor

Lean business processes integrated with mobility offer efficiencies on the shop floor for manufacturers. ...

... "While thousands of companies have used the tools of Lean such as Value Stream Mapping to re-engineer business process, rarely did those analyses well-consider the possibilities of mobile, connected workers. " ...

Via Supply Chain Digest: Mobility

Lean Dentistry

Local dentist uses lean techniques to streamline his office processes, delighting customers, and achieving recognition by the Shingo Prize. ...

... "For the dental office, this means small things - like arranging sterilization areas in a way that minimizes steps - as well as large things. One of the biggest differences at Bahri's office, for example, is that patients don't move from room to room or have to deal with multiple appointments ... " ...

Via Florida Times-Union, Jacksonville: Business Lean Success Story

Lean MES Manufacturing Execution Software Makes Inventory Visible

Manuvis introduces software version that integrates real-time inventory visibility and production metrics in dynamic operational dashbboard. The data visualization supports value stream mapping, queue performance monitoring, and asset utilization. ...

... "Whereas most manufacturing execution systems (MES) and enterprise manufacturing intelligence (EMI) solutions focus on production machine output, few offer inventory visibility. Manuvis' FactoryMRI, built on lean manufacturing principles, offers superior analytical tools that simplify information exchange within an enterprise and provides a common way to help synchronize enterprise assets. These tools help eliminate waste and increase profits, whether uncovering process variations that cause quality defects, identifying sources of waste and helping find untapped capacity. And since data is obtained directly from production machines, total cost of ownership is reduced by eliminating the need for human data entry into PC's or operate bar code equipment. " ...

Via Manuvis: Real-Time Lean Manufacturing Capabilities

Lear Lean Manufacturing Implementation Drives Operational Efficiency Gains

Lear Corporation's lean manufacturing processes have driven productivity and operational efficiency for the company. Lear's lean implementation concentrates on the work environment, quality, the layout, and the flow of materials. ...

... "Tony Coomer, the company's vice president of Advanced Manufacturing and Continuous Improvement-Seating Systems, said lean manufacturing techniques have been deployed throughout the company's global manufacturing network.

Lear employees are trained on LMS during a three-week workshop. The training is conducted at all Lear plants by a lean manufacturing leader and employees receive LMS certification upon successful understanding of LMS principles and validation of model line projects which deploy LMS.

Product design is another key element in Lear's Lean Manufacturing System. Product design teams rely on LMS principles to ensure products can be manufactured in a lean environment. Approximately two thirds of product costs are locked into the initial design of the product, Coomer noted, so any effort to reduce cost after the initial design stage can only influence the remaining one third of the product's overall cost. At one facility, for example, product design teams incorporating design for lean principles in a model year change realigned workstations, changed production flows and made other assembly line changes to boost productivity.

Plant layout also plays an important role in Lear's approach to lean manufacturing. Lear uses Value Stream Mapping (VSM) to understand work flow and identify waste. In addition, extended VSM allows Lear to eliminate waste from the entire value stream -- from supplier to customer. VSM encompasses items such as freight costs, inventory controls and production changes. " ...

Via Lear Corp: Lean Manufacturing System Hikes Productivity and Reduces Costs

Lean Through The Value Stream

Lean is not just relegated to the plant floor. ...

... "If you're going to consistently beat your competition to market on this newly expanded, worldwide playing field you've got to spread Lean throughout your entire value stream. " ...

Via InformationWeek: Infor on Lean Supply Chain

iGrafx Software For Six Sigma Business Process Improvement

iGrafx releases 2007 version of its solutions for process excellence, that enhances modeling, simulation, mapping, and Lean Six Sigma support. ...

... "Improved Lean and Six Sigma Support: iGrafx 2007 offers great new features for Lean users including the ability to create Extended Value Stream Maps to obtain a lean view that crosses plant, divisional, and company boundaries. Six Sigma enthusiasts, on the other hand, will use the new Prioritization and Failure Mode Spreadsheets to spotlight improvement opportunities and mitigate failure mode effects faster. Users will also be able to define and scope Six Sigma projects, and identify progress towards process goals with the use of iGrafx Process Central repository. " ...

Via iGrafx: iGrafx 2007 Product Suite Enables Enterprise Business Process Improvement

Value Stream Map Workshop

Pelion offers one-day value stream mapping workshops ...

... "Initial one-day workshops will be led by Pelion's Chief Technology Officer Dave Gleditsch, a 30-year manufacturing industry veteran who has driven some of the world's most successful Lean transformation programs. The course is conducted in a teach & do format where students will learn in class how to create Value Stream Maps of both current and future states considering product flow strategies and customer value as the compelling drivers. Appropriate Lean Manufacturing principles will be used along the way as students work to define the current state, identify wastes and opportunities and discuss how Lean tools can be applied to create a Future State Map with an improvement plan. " ...

Via Pelion Systems: Value Stream Mapping: Beyond Whiteboards Workshop

Six Sigma Mission Excellence

Mission excellence will be based on a foundation of Six Sigma in this new organizational model. ...

... "Northrop Grumman Corporation has appointed Sonya Sepahban to lead the newly created Mission Excellence organization at its Space Technology sector. The organization combines Six Sigma, Safety & Mission Assurance, and Chief Engineer functions into one organization. Sepahban will be responsible for advancing the maturity and performance of the sector's processes, increasing the cross-functional focus on production reliability and quality, and the focus on customer deliverable products. The new organization will emphasize collaboration across the value stream to ensure mission success with stable, predictable processes to ensure flawless execution. " ...

Via Northrop Grumman: Northrop Grumman Assigns Sonya Sepahban to Lead Space Technology Sector's New Mission Excellence Organization

Value Stream Mapping Workshop: Lean Manufacturing Principles ...

... "A lean manufacturing workshop, Value Stream Mapping & Lean Manufacturing Principles, will be held from 8 a.m. until 3 p.m. at The Center at Purdue University Calumet. Cost is $125 per participant and includes continental breakfast and lunch buffet. " ...

Value Stream Mapping Workshop: Lean Manufacturing Principles: Via Northwest Indiana News: Business Calendar ...

Six Sigma Flowchart Software ...

BreezeTree Software releases FlowBreeze 1.0, a flowcharting software add-in for Microsoft Excel, which should be a useful product for flowcharting Six Sigma business processes. ...

... "The product marks the launch of the first in a series of flowcharting, process mapping and value stream mapping tools that BreezeTree Software will release in the coming year. The products will be targeted at professionals in the ISO 9000, Six Sigma, and Lean markets. " ...

Six Sigma Flowchart Software: Via BreezeTree: BreezeTree Software Announces the Release of FlowBreeze Flowcharting Software: BreezeTree Software Launches FlowBreeze 1.0, an Innovative Flowcharting Tool for Microsoft Office Users ...

SixSigma Master Black Belt Position Available: Quality Improvement Career ...

Position is available for a master black belt in Six Sigma ...

... "MASTER BLACK BELT: Lead the Six Sigma Program. Develop and conduct training plans; serve as the Six Sigma technical expert; maintain Six Sigma tool application and methodology integrity; benchmark Six Sigma best practices; ensure that projects are adequately scoped, assigned, and implemented; allocate GB and BB resources. LEAN EXPERT: Lead cross-functional teams to implement Lean solutions; contribute to the identification and prioritization of Lean opportunities; lead the analysis of root cause solutions; support the implementation of Lean metrics across sites; support the identification and documentation of best practices; support the development of training for value stream mapping and Lean Sigma tools. " ...

SixSigma Master Black Belt Position Available: Quality Improvement Career: Steelscape: Via The Daily News Online

Kaizen Blitz: Improvement Technique ...

Business, everywhere, can benefit from continuous improvement. Products, processes, and people can improve quality. Fred Fishman, Manager Strategic Procurement Programs, explores the techniques of continuous improvement, such as recognizing the opportunity and seeking assistance. ...

... "Whether portrayed in a formula-rich analysis during a Six Sigma event, the rapid fire and instinctive physical changes implemented during a kaizen blitz, the reduction of muda (Japanese term for waste) in the lean journey, or the methodical development of a value stream map to visually identify value-added vs. non-value-added steps in a flow of work, each technique employs some variation of mathematical, statistical or visual analysis to achieve the desired result - improvement. " ...

Kaizen Blitz: Improvement Technique: Via Reliable Plant Magazine: The importance of Continuous Process Improvement ...

Value Stream Mapping Seminar This Week ...

... "The Michiana Chapter of APICS, the Association for Operations Management, will meet Tuesday at the Upper Deck, Coveleski Stadium. Bob Montgomery, CPIM, will speak on Value Stream Mapping. " ...

Value Stream Mapping Seminar This Week: Via South Bend Tribune: Business Meetings and Seminars ...

Kaizen Event: 5S Implementation ...

Kaizen 5S process at Stevens Industries reduced cycle times, travel distance, and space requirements, while increasing the production capacity. ...

Kaizen Event: 5S Implementation: Via NIST: Stevens Industries International, Inc.: MEP Providing Hands-On Help through Florida Manufacturing Extension Partnership ...

... "Florida MEP worked with Stevens' management team in introducing the principles of lean manufacturing to key employees by presenting a TimeWise Lean 101 workshop thereby providing all team members with the knowledge and necessary tools to advance to the next stage of lean transformation. Stevens then moved on with a Computerized Process Model of their counter top shop in Fort Meyers to evaluate the process in their counter top facility. A value stream map was then created for the Cabinet Manufacturing line, which resulted in a Kaizen event and a 5S-implementation process. The Stevens' Lean Team implemented the basics of lean (5S's, standardized work, quality at the source, pull/kanban systems). " ...

Kaizen Events: 5S of Raw Material and Shipping Process

MEP supported the implementation of multiple Kaizen events on the raw material process and shipping area for Cedarworks. First pass yield was increased, cycle time was reduced, and space was increased through operational efficiencies gain through kaizen. ...

Kaizen Events: 5S of Raw Material and Shipping Process: Via NIST: Cedarworks: Assistance to Cedarworks ...

... "Cedarworks' 45 employees participated in Maine MEP's Timewise Lean 101 in order for all to understand the concepts behind Lean Manufacturing. A Value Stream Map of the manufacturing process from product receipt to wrapping for shipment was conducted, as well as a Value Stream Map of the Sales and Customer Service processes. Two Kaizen events were conducted as a result of the Value Stream Map process. One Kaizen event was a 5S of the raw material grading area and the other was a 5S of the shipping area. The Value Stream Map revealed a huge problem with the raw material being received and a problem with the flow of the material in the grading area. " ...

Lean Manufacturing Seminar Series: California ...

EMS will provide lean manufacturing seminars in California starting in early 2006. ...

Lean Manufacturing Seminar Series: California: Via EMS Consulting: EMS Consulting Group Announces a Series of Lean Manufacturing Seminars and Workshops in Southern California

... "EMS Consulting Group, Inc. has announced a public Lean Manufacturing certificate program beginning in February 2006 in Orange County, CA. The program will assist manufacturers with the challenge of implementing lean and maintaining continuous improvements. It includes a series of eight course modules designed to provide participants with targeted managerial and technical competencies in lean manufacturing. Participants will learn how to apply the key techniques of lean manufacturing: Value Stream Mapping, Lean Production Control and Inventory Management, One-Piece Flow, Cellular Manufacturing, Material Flow and Kanban, Five S, and Kaizen Events and tools. Lean Certification also includes the completion of lean manufacturing projects at attendee companies to reinforce the classroom learning.

The program will take place at the Doubletree Club Hotel Orange County Airport in Santa Ana, CA in eight Thursday sessions. The dates are February 2, 23; March 9, 23; April 6, 20; and May 4, 18. The sessions will run from 8:30 am to 4:30 pm. " ...

Lean Manufacturing: Visual Map ...

The value stream map can be used to design a vision for the future manufacturing process and enable a collborative environment on the shop floor ...

Via TMAC: Value Stream Mapping ...

... "Visually describes the flow of material and information through a manufacturer's entire production systems. This allows for better understanding of the complete process. By graphically portraying the process, one is able to see exactly where value is added and value is lost. " ...

Lean Waste Elimination Program ...

Lean Waste Elimination Program: Commander, Naval Air Force, U.S. Pacific Fleet: History and Background of NAVRIIP and AIRSpeed ...

... "Lean: A focus on the removal of waste, which is defined as anything not necessary (no value added) to produce the product or service. Lean is a process improvement strategy that facilitates an organization's ability to make everything, everyday in the exact quantity required, with no defects. The goal is to achieve perfection through the total elimination of waste in the value stream. Lean uses incremental improvement to constantly expose waste to balance operational and standard workflows. Most notable examples are the supply chains established by Toyota and Honda. " ...

Lean Value Stream Mapping ...

Lean Value Stream Mapping: SEPO Upcoming Events

... "Lean (originally, Lean Manufacturing) is focused on eliminating waste and non value added activity throughout the value stream in order to reduce cycle time, cost, and variance. Value stream mapping is following a product or service from beginning to end and drawing a visual representation of every process in the material and information flow for the current state to understand how things currently operate (our baseline). Next, create a future state mapping of how value should flow (our vision). The assumption is that you can get better results from average people using brilliant processes than from brilliant people using broken processes. " ...

Innovative Use Lean Processes ...

Innovative Lean Processes ...

... "Multiple methods are used to identify, evaluate and implement process improvements within the current process method context. Each process owner is responsible for maintaining and improving processes based on the organization's business goals and project requirements. ACS has implemented and additional approach to process improvement to supplement and enhance the existing process by applying Lean principles. Process improvements are identifies and prioritized on customer value through a method called value stream analysis. " ...

Lean Initiative: Five Basics of Lean Thinking ...

Lean Initiative

... "The lean philosophy employs five basic principles of lean thinking: (1) specify value from the perspective of the end customer, (2) identify the value stream for each product, (3) create continuous flow of the product, (4) let the customer pull the product and (5) strive for perfection. Lean is intended to attack muda (Japanese for waste) and give customers exactly what they want, when they want it and perform tasks more and more effectively. " ...

Lean Manufacturing Certification Program ...

EMS Consulting Group, Inc. Announces Lean Manufacturing Certification Program in San Diego

... "EMS Consulting Group, Inc. has just announced a public Lean Manufacturing certificate program for this fall in North San Diego County. The program will assist manufacturers with the challenge of implementing lean and maintaining continuous improvements. It includes a series of six course modules designed to provide participants with targeted managerial and technical competencies in lean manufacturing. Participants will learn how to apply the key techniques of lean manufacturing: Value Stream Mapping, Lean Production Control and Inventory Management, One-Piece Flow, Cellular Manufacturing, Material Flow and Kanban, Five S, and Kaizen Events and tools. Lean Certification also includes the completion of lean manufacturing projects at attendee companies to reinforce the classroom learning. The program will take place at the Grand Pacific Palisades Hotel in Carlsbad, CA in seven Wednesday sessions. The dates are September 7, 21; October 5, 19; November 2, 16, 30. The sessions will run from 8:30 am to 4:30 pm. These training sessions may also be taken separately. To register or obtain additional information, visit www.lean-manufacturing-training.com and view the public workshop schedule. " ...

Lean Process Transformation ...

U.S. Department of Defense Transformation Story - Understanding the Lean Process

... "To understand the Lean process, you must be able to recognize a value stream, define Six Sigma and Theory of Constraint. To define a value stream you must know that it includes all the steps (both value added and non-value added) in a process that the customer is willing to pay for in order to bring a product, or service through the main flow essential to producing that product or service. " ...

Lean Manufacturing Techniques: Produce Positive Results ...

Plunge into Lean Manufacturing Helps Pelican Wire Increase Sales, Add Staff: Incorporating Lean Techniques Results in Six Figure Savings and Sales for Naples Company ...

... "To help identify areas to make changes and provide the necessary training to produce positive results, Pelican Wire called on the Florida Manufacturing Extension Partnership (Florida MEP) to help implement Lean Manufacturing techniques. Lean Manufacturing is an implementation technique that utilizes simple but effective methods to identify and reduce waste, and inventories, clear shop floors and streamline production processes all with a goal of decreasing costs and increasing productivity. Working with staff and management, David Ferguson and Jerry Nelligan, project managers for the Florida MEP, started with a Value Stream Map which literally mapped the flow of work through beginning to end of production line of a product for one of Pelican's main customers. " ...

The Florida MEP is an affiliate of the National Institute of Standards and Technology (NIST) under the U.S. Department of Commerce. The national MEP is a network of manufacturing extension centers that provide business and technical assistance to smaller manufacturers in all 50 states, the District of Columbia and Puerto Rico. Through MEP, manufacturers have access to more than 2000 manufacturing and business “coaches” whose job is to help firms make changes that lead to greater productivity, increased profits, and enhanced global competitiveness. For more information on the Florida MEP program call 321-939-4000.

Microsoft Supports Lean Manufacturing Software Capability in Automotive Industry ...

Microsoft Drives Insight and Innovation for the Automotive Community With Peak Performance Initiative

... "At the Microsoft Global Automotive Summit,Microsoft Chairman and Chief Software Architect Bill Gates teamed with Microsoft Corp.'s automotive team in announcing the Peak Performance Initiative, designed to help the automotive community accelerate insight through advanced analysis services, drive innovation through collaboration, and improve performance via increased visibility into operations across the automotive supply chain. ... Automotive OEMs and suppliers are under tremendous pressures to improve performance in a highly competitive, cost-sensitive environment. To succeed, these companies are looking for solutions that cut across and integrate the entire value stream. In support of Microsoft's Peak Performance Initiative, we are coupling Microsoft technology with Avanade's holistic enterprise expertise to meet the challenges of the automotive industry. Avanade's solutions enable collaborative product design, demand-driven lean manufacturing and supply management, global sourcing, and global operations management. " ...

-- Michael Merfeld, Solution Director, Microsoft Business Solutions, Avanade

Microsoft has been working with the automotive industry for more than a decade. In manufacturing, Microsoft works with industry-leading partners to develop solutions based on Microsoft technologies that enable OEMs, suppliers and customers to improve efficiency, effectiveness and knowledge across the business. Through business applications, .NET technologies and enterprise platform support, manufacturers are able to accelerate time to market, collaborate globally with engineers, reduce costs by leveraging the power of the Internet, and increase visibility into their production and supply chain processes. From an in-vehicle technology perspective, Microsoft's Automotive Business Unit works collaboratively with the auto industry to deliver technology designed for advanced in-car information, navigation and entertainment systems. Microsoft technology is on the road today in 25 preinstalled and aftermarket devices from 13 world-class automakers and suppliers, including Acura, BMW, Citroën, Clarion, Fiat, Subaru, Honda, Hyundai, DaimlerChrysler, Mitsubishi, NexTech, Toyota and Volvo.

Lean Enterprise Simulation Model ...

Simulation Model of the Lean Manufacture of NIF Assemblies

... "The concept of Lean Manufacturing, which was pioneered at Toyota, emphasizes continuous improvement through the identification of the value stream and the reduction of waste, and making value flow at the pull of the customer. The Lean concepts have been applied to many manufacturing applications in industry, most notably the major automotive plants. The NIF Lean Enterprise Team at Lawrence Livermore National Laboratory is working to apply the concepts of Lean Manufacturing to the production of the mechanical and optical assemblies which will comprise the NIF system. Application of the Lean concepts requires the identification of the value stream, along with streamlining of the production process, such that unnecessary steps are eliminated, and production flows according to the demand schedule in a 'just-in-time' manner." ...

Kaizen Strategy: Lean Manufacturing

Waste Minimization: Lean Manufacturing

... "The kaizen strategy aims to involve workers from multiple functions and levels in the organization in working together to address a problem or improve a particular process. The team uses analytical techniques, such as Value Stream Mapping, to quickly identify opportunities to eliminate waste in a targeted process. The team works to rapidly implement chosen improvements (often within 72 hours of initiating the kaizen event), typically focusing on ways that do not involve large capital outlays. Periodic follow-up events aim to ensure that the improvements from the kaizen blitz are sustained over time. Kaizen can be used as an implementation tool for most of the other lean methods." ...

Lean Initiative: The initiative covers an area of improvement of the product process from concept to operations use of turbine engines in military air

Lean Initiative

... "The principles of lean thinking were first documented in the U.S. by researchers from MIT International Motor Vehicle Program and in the book 'The Machine That Changed the World' by James Womack, Daniel Jones and Daniel Roos. The lean philosophy employs five basic principles of lean thinking: (1) specify value from the perspective of the end customer, (2) identify the value stream for each product, (3) create continuous flow of the product, (4) let the customer 'pull' the product and (5) strive for perfection. Lean is intended to attack muda (Japanese for waste) and give customers exactly what they want, when they want it and perform tasks more and more effectively. " ...

Lean Principles Pilot Program

DECD: Connecticut Tooling and Machining Manufacturers Awarded $36,700 for Pilot Program

... "CTMA plans to conduct lean practice training, assessments, value-stream mapping and kaizen events on behalf of its participating companies, leading to greater penetration of lean principles among member companies. The following CTMA companies currently plan to participate in the pilot program: AcuCut Inc. (Southington), Edward Segal Inc. (Thomaston), Fairchild Automated Parts (Winsted), Hobson & Motzer Inc. (Durham), Hygrade Precision Technologies Inc. (Plainville), and Signature Mold and Manufacturing Company Inc. (Glastonbury)." ...

Lean Manufacturing Training Workshops ...

Lean Manufacturing Training Workshops: Lean Manufacturing Training from Brookline Company Helps Local ...

Upcoming lean manufacturing workshops ...

From PR Newswire (press release) ... LEI) will help industry and suppliers in the Boston region cut costs, improve profits, and defend jobs by eliminating waste through lean manufacturing. ...

... A series of workshops presented by the Brookline-based nonprofit Lean Enterprise Institute (LEI) will help industry and suppliers in the Boston region cut costs, improve profits, and defend jobs by eliminating waste through lean manufacturing. The series of seven workshops, including new ones on value-stream mapping for offices and healthcare, will run March 29-31 at the Wyndham Boston hotel, Boston, MA. ...

Lean manufacturing cuts costs and inventories rapidly to free cash and resources, which is critical in a competitive world economy. Lean supports growth by improving productivity and quality, reducing lead times, and freeing resources. For example, it frees office and plant space and increases capacity so companies can add product lines, in-source component production, and increase output of existing products. Companies implementing lean can take advantage of renewed economic growth by increasing sales while controlling costs. Based in Brookline, MA, the Lean Enterprise Institute is a nonprofit training, publishing, and research organization founded by James Womack, Ph.D., in August 1997. It has developed simple but powerful tools for implementing a set of ideas known as lean production and lean thinking, based initially on the Toyota Production System and now extended to an entire Lean Business System.

Value Stream Optimization Increases Production One Hundred Percent ...

OH Impact 18: MEP Helps Pro-Pak Industries Increase Production One Hundred Percent

... "NIST's Manufacturing Extension Partnership (MEP) affiliate developed a unique three-prong training program for Pro-Pak that combined instruction in lean manufacturing principles, teamwork, problem solving, and value stream mapping into one integrated package. Twelve employees from management and operations trained on Saturdays to avoid interrupting production. In the end, the team determined that the equipment problem could be alleviated with a new die cut anvil, adding glue detection sensors and blanket printing plates. " ...

Supplier Lean Training ...

Governor Locke's Speeches | Washington State Supplier Lean Training Kick-off Event

... "Raising and enhancing the skill level of manufacturing workers within all tiers of the value stream will make our suppliers even more competent. And more competitive with other states, and other countries. Strengthening our manufacturing excellence will more competitively position us to earn more manufacturing work. Including the 7E7. Boeing has long been a leader in lean manufacturing. From the Japan Study Missions more than a decade ago to sweeping changes in processes and techniques in the factory the past several years, Boeing has shown the courage and foresight to change and improve. " ...

Value Stream Mapping Supports Lean Principles ...

DECD: Connecticut Tooling and Machining Manufacturers Awarded $36,700 for Pilot Program

... "With the project slated for completion by October 1, CTMA plans to conduct lean practice training, assessments, value-stream mapping and kaizen events on behalf of its participating companies, leading to greater penetration of lean principles among member companies. The following CTMA companies currently plan to participate in the pilot program: AcuCut Inc. (Southington), Edward Segal Inc. (Thomaston), Fairchild Automated Parts (Winsted), Hobson & Motzer Inc. (Durham), Hygrade Precision Technologies Inc. (Plainville), and Signature Mold and Manufacturing Company Inc. (Glastonbury)." ...

Pollution Prevention Lean Value Stream ...

Pollution Prevention - P2 Programs:Green Suppliers Network

... "Lean and Clean. Using Lean & Clean manufacturing practices, your GSN review team will focus on incorporating energy and materials efficiency and process optimization into the supply chain, which in turn can lead to substantial environmental benefits and reductions in labor and capital costs. The 360vu Review will produce process and value stream maps of a selected process in each facility." ...

Lean Value Stream for NIF Assemblies

Simulation Model of the Lean Manufacture of NIF Assemblies

... "The concept of Lean Manufacturing, which was pioneered at Toyota, emphasizes continuous improvement through the identification of the value stream and the reduction of waste, and making value flow at the pull of the customer. The Lean concepts have been applied to many manufacturing applications in industry, most notably the major automotive plants. The NIF Lean Enterprise Team at Lawrence Livermore National Laboratory is working to apply the concepts of Lean Manufacturing to the production of the mechanical and optical assemblies which will comprise the NIF system. Application of the Lean concepts requires the identification of the value stream, along with streamlining of the production process, such that unnecessary steps are eliminated, and production flows according to the demand schedule in a 'just-in-time' manner." ...

Business Process Improvement Reinvents The Value Stream ...

FAA Business Process Improvement

... "BPI applies a structured methodology defining an organization's as-is environment and models a to-be set of processes that add value to the organization's mission and objectives. Improvements are made, using these processes and data models as a road map, and technology is applied as needed to enable these identified solutions. The goal of BPI is to improve the quality, availability, effectiveness, and cost of business processes within the agency. BPI is focused on completely understanding the customer's needs, identifying means to meet those needs, and then reinventing the value stream. "

Value Stream Air Permitting Process Is A Success ...

New DEQ Air Permitting Process: A Success For Michigan

... "the Michigan Department of Environmental Quality (DEQ) announced that it had re-engineered its air quality Permit to Install (PTI) application review process. This process, done using a brainstorming technique called value stream mapping, brought industry representatives together with the DEQ's Air Quality Division staff to work toward a goal of streamlining and simplifying the PTI application process. The new process emphasizes earlier face-to-face meetings between permit applicants and DEQ staff, clear communication of application requirements, early identification of any outstanding permit-related issues, and will allow the DEQ to encourage early public involvement. " ...

Value Stream Process Map Plans The Lean Journey ...

Value Stream Mapping at MEP Source For Manufacturers ...

... "What is Value Stream Mapping? Value Stream Mapping is a tool used to create a material and information flow map of a product or processes. This powerful tool allows companies to map the flow of products in the back door as raw material, through all manufacturing process steps, and off the loading dock as finished product. This is the Value Stream. You begin the journey with the current state map - it shows you where you are. Then, you plan you lean journey with a future state map - it shows you where you're going and how you're going to get there. based on your Value Stream Map, you can streamline work processes, thereby cutting lead times and reducing operating costs. " ...

Waste Minimization Kaizen Methods ...

Waste Minimization: Lean Manufacturing ...

From EPA ...

... "Kaizen, or rapid improvement processes, are often considered to be the building block of all lean production methods. Kaizen focuses on eliminating waste in the targeted systems and processes of an organization, improving productivity, and achieving sustained continual improvement. This philosophy implies that small, incremental changes routinely applied and sustained over a long period result in significant improvements. The kaizen strategy aims to involve workers from multiple functions and levels in the organization in working together to address a problem or improve a particular process. The team uses analytical techniques, such as Value Stream Mapping, to quickly identify opportunities to eliminate waste in a targeted process. The team works to rapidly implement chosen improvements (often within 72 hours of initiating the kaizen event), typically focusing on ways that do not involve large capital outlays. Periodic follow-up events aim to ensure that the improvements from the kaizen blitz are sustained over time. Kaizen can be used as an implementation tool for most of the other lean methods." ...

Goodrich Lean Manufacturing Pays Off ...

SignOnSanDiego.com -- Goodrich division lands Airbus contract: Bruce V. Bigelow, San Diego Union-Tribune, writes... Recent contract wins by Goodrich have invigorated the viability of the Aerostructures Group and have validated the company's lean manufacturing transformation which is contributing to an increase in operational efficiency.

... Goodrich Aerostructures Group started in 1940 as Rohr Aircraft. Learn more about our proud history as a leading designer, producer and integrator of nacelle systems and other aerospace products. Since August 1996, the Aerostructures Group has been implementing Lean Manufacturing methods throughout all aspects of the business. Based on the Toyota Production System, Lean Enterprising solicits every employee's involvement in defining each product's value stream - the series of specific activities needed to get from raw material to finished item. The Group then uses week-long Lean events involving employees, customers, and suppliers to eliminate unnecessary steps from every value stream. The result? Through the use of Lean tools, the Aerostructures Group has realized 50% improvements in product build hours and flow times in many areas. The Group has also been able to support dramatic customer production rate increases and also absorb additional work with no increase in resources. ...

Plant Floor Data Collection Enables Lean Manufacturing Practices ...

Plant Floor Data Collection Enables Lean Manufacturing Practices: Kaba Benzing America to Resell Epic Data's MPT9100 Data Collection ...

From Business Wire (press release), CA ... The MPT9100 offers users enhanced productivity and security and full support for lean manufacturing practices. Features include ...

... Epic Data International Inc. (TSX:EKD) announced today that it has entered into a reseller agreement for the MPT9100(TM) data collection workstation with Kaba Benzing America, Inc., the North American operating subsidiary of Kaba Holding AG (Swiss: KABN) and a leading global provider of time and attendance, access control and production data collection systems. ...

Located in Miramar, Florida, Kaba Benzing America, Inc., is a subsidiary of US$900 million Kaba Holding AG and a worldwide leader in time and labor management systems. From touch screen access and shop floor terminals to complex labor costing algorithms and reporting for SAP R/3 and other leading enterprise systems, Kaba Benzing offers an array of time and attendance and production data collection solutions. For 30 years Epic Data has been a leader in automatic identification and data collection solutions for the world's most progressive aerospace, automotive, high technology and industrial equipment & machinery manufacturers. We increase plant productivity and velocity while identifying the continuous improvement initiatives vital to winning in today's competitive manufacturing environments. Epic Data's enterprise mobility solutions for parking enforcement and route management increase productivity while improving customer service and worker safety by connecting mobile personnel to central offices in real time. People and technology make Epic Data a global leader in automated data collection solutions for the extended enterprise.

Additional resources on plant floor data collection and lean manufacturing ...

Lean Manufacturing Program Management: examine the Value Stream from order entry to release to the plant floor. ... Lean is in 35.7% of US plants (Industry Week survey) and, if you ... For more information. ...

Quality 101: Data Collection Serves: range for small and mid-sized plants and have ... Because of this, plant managers often find it cumbersome to ... are not a cure-all for factory floor problems and ...

Real-Time Manufacturing Applications Strategies For Reducing: File Format: PDF/Adobe Acrobat ... exposure, make lean manufacturing practices more effective ... Existent plant floor applications in automotive ... manufacturing control, data collection, warehousing ...

Lean Manufacturing Principles: Surviving and Thriving with California's High Energy Costs; CMTC ...

Lean Manufacturing Principles: Surviving and Thriving with California's High Energy Costs; CMTC ...

From Business Wire (press release), CA ... Through a unique tool, termed Value Energy Stream Mapping (VeSM), CMTC consultants have applied Lean Manufacturing principles to manufacturers' operations ...

... Every manufacturer has had to absorb the increased energy costs associated with reduced electricity supply and increased demand. Yet, a growing number of companies are beginning to insulate themselves from energy costs and reduce their own demand for electricity with some help from California Manufacturing Technology Consulting (CMTC). Through a unique tool, termed Value Energy Stream Mapping (VeSM), CMTC consultants have applied Lean Manufacturing principles to manufacturers' operations, reducing energy usage and in some cases saving these businesses tens of thousands of dollars on their electricity bills. As most manufacturing businesses tend to be high energy consumers, the VeSM tool not only makes companies more productive, it also makes them more energy efficient. ...

California Manufacturing Technology Consulting: A private, nonprofit corporation, CMTC was established in 1992 to provide high value consulting services to California's high tech and traditional small- and medium-size manufacturers to increase their competitive advantage through improved methods of management and manufacturing. Today, through its seven regional teams, CMTC provides consulting services in the practice areas of Strategic Business, Lean Enterprise, Information Technology, Energy Services, Quality and Supply Chain Management. CMTC's regional teams cover Los Angeles, the Inland Empire, Orange County, Ventura/Santa Barbara County, the San Fernando/San Gabriel Valley, the San Joaquin Valley and San Diego/Imperial County.

Taiichi Ohno: Lean Initiative

From AFMC/industry team looks for turbine engine improvements ...

... "The philosophy, Lean Production, was pioneered by Toyota executive Taiichi Ohno and used in the Toyota Production System. The principles of lean thinking were first documented in the U.S. by researchers from MIT International Motor Vehicle Program and in the book 'The Machine That Changed the World' by James Womack, Daniel Jones and Daniel Roos. The lean philosophy employs five basic principles of lean thinking: (1) specify value from the perspective of the end customer, (2) identify the value stream for each product, (3) create continuous flow of the product, (4) let the customer 'pull' the product and (5) strive for perfection. " ...

Value Stream: F-16 maintainers educate, motivate to transform processes

From AFMC Public Affairs Link ...

... "With the education goal in their sites, core team members and the SwRI consultants began with an area assessment that included developing a value stream map to illustrate the value-added, and the non-value-added steps in the wing repair process, Dugan said. They also conducted numerous training sessions to teach both management and shop employees essential Lean tools which emphasize workplace organization and cleanliness. After the initial training sessions were complete, a detailed value stream map analysis showed that a major area of improvement could be found in the pylon rib assembly process, he said." ...

Value Stream: FAA Business Process Improvement

From FAA Business Process Improvement ...

... "BPI applies a structured methodology defining an organization's as-is environment and models a to-be set of processes that add value to the organization's mission and objectives. Improvements are made, using these processes and data models as a road map, and technology is applied as needed to enable these identified solutions. The goal of BPI is to improve the quality, availability, effectiveness, and cost of business processes within the agency. BPI is focused on completely understanding the customer's needs, identifying means to meet those needs, and then reinventing the value stream. " ...

The Federal Aviation Administration (FAA) is responsible for the safety of civil aviation. The Federal Aviation Act of 1958 created the agency, under the name Federal Aviation Agency. The FAA issues and enforces regulations and minimum standards covering manufacturing, operating, and maintaining aircraft.

Value Stream: Electric Boat Corporation, Quonset Point Facility - North Kingstown, RI:Electrical Panel Manufacturing

From BMP Surveys Online ...

... "Electric Boat Corporation, Quonset Point Facility (EBQP) reconfigured and relocated its Electrical Manufacturing Shop using Lean Manufacturing techniques and a team of functional experts most familiar with the process. Prior to this change, the shop was remote from other manufacturing activities, mostly the Sheetmetal Shop and Test to Inspect workstations. The team performed a value stream analysis of the flow process and determined that the Electrical Manufacturing Shop should be relocated closer to the Sheetmetal Shop and the test area should be co-located in the Electrical Manufacturing Shop. In its new location, the travel distance between shops has been reduced and the coordination has improved. " ...

The Office of Naval Research's Best Manufacturing Practices (BMP) Program was created in 1985 to help businesses identify, research, and promote exceptional manufacturing practices, methods, and procedures. Its objective is to empower defense and commercial customers to operate at a higher level of efficiency and effectiveness. The Office of Naval Research coordinates, executes, and promotes the science and technology programs of the United States Navy and Marine Corps through schools, universities, government laboratories, and nonprofit and for-profit organizations. It provides technical advice to the Chief of Naval Operations and the Secretary of the Navy and works with industry to improve technology manufacturing processes.

Value Stream: MEP Helps Pro-Pak Industries Increase Production One Hundred Percent

From NIST, Office of the Director ...

... "NIST's Manufacturing Extension Partnership (MEP) affiliate developed a unique three-prong training program for Pro-Pak that combined instruction in lean manufacturing principles, teamwork, problem solving, and value stream mapping into one integrated package. Twelve employees from management and operations trained on Saturdays to avoid interrupting production. In the end, the team determined that the equipment problem could be alleviated with a new die cut anvil, adding glue detection sensors and blanket printing plates. " ...

NIST is a non-regulatory federal agency within the U.S. Commerce Department's Technology Administration. NIST's mission is to develop and promote measurement, standards, and technology to enhance productivity, facilitate trade, and improve the quality of life.

Value Stream: ESBI - Program ...

From Air Force Research Laboratory, Manufacturing Technology (AFRL/ML) ...

... "The ESBI team has chosen instead to use lead-time reduction, cycle time reduction and process variability reduction as the measures of impact. Multiple attempts have been made to address these issues. These include ad hoc briefings to Air Force management, bellwether parts analyses and detailed value stream analysis in the BP&P arena. " ...

For over 85 years, the men and women of the Air Force Research Laboratory have sought to make a better flying machine. Since 1917, when the directorate was activated as the Materials Section of the U.S. Army Signal Corps at McCook Field in Dayton, Ohio, the Materials and Manufacturing Directorate and its predecessors have played key roles in research and development efforts that have advanced aerospace capabilities to where they are today.

Value Stream: Lean Value Course ...

From ELearning at Department of Commerce ...

... "learn about value-stream mapping - a technique designed by several forefounders of the lean manufacturing movement. Applying this technique to identify waste, create an ideal value stream and initiate lean projects will be the culmination of your new-found knowledge. " ...

E-Learning@DOC provides for a shift from traditional "ad hoc" training to a comprehensive, web-enabled, agency-wide employee development system which provides information about and administers training from e-learning to instructor-led courses. The availability of this form of continuous learning will provide a means for DOC employees to keep up with changes in mission, technology, and content of work, and serve to attract and retain employees for whom self-development is a top priority.

Value Stream: LEAN THINKING LEADS THE WAY TO

From Fort Monmouth NJ Army C4ISR, Rosemary Dellara, DCSOPS, writes ...

... "the CECOM Deputy Chief of Staff for Operations' Lean Implementation Office has tracked major accomplishments at the Tobyhanna Army Depot, the DoD's largest facility for the repair, overhaul, test, design, and fabrication of communications-electronics systems and components. Value Stream Analysis on the Sidewinder (AIM-9) guidance and control section overhaul line and the AN/TRC-170 communication system overhaul line marked the first of many lean team events. Both systems experienced marked improvement in materiel movement, flow days and unit maintenance costs. " ...

Lean Value Stream: Resource Management

From Robins Air Force Base, Air Force Materiel Command ...

... "By 1950, the Japanese, who greatly admired Henry Ford, established the Toyota Production system that began to eliminate waste from the process. In the 1970s, the Japanese continued to implement American principles by Juran, Deming, Shewhart, and Crosby at Toyota. By 1980s, Americans took notice of the loss of market share of automobiles, shipbuilding, electronics, avionics, office equipment, etc., and embraced Quality. By the late 1980s, Toyota had nearly achieved Lean. Over the years, the Air Force explored various programs such as Zero Defects, Meaningful Measures of Merit, Total Quality Management, and QP4 in an effort to streamline processes and eliminate waste. By 1990, the focus became Lean Principles with the establishment of five principles: Value, Value Stream, Flow, Pull, and Perfection. By 2000, Lean was used in Production, Services and Remanufacturing. With Lean, the customer determined the first principle to be value, based on cost, quality, and delivery. " ...

Robins Air Force Base, home of Warner Robins Air Logistics Center and more than 60 other units that make up a vital part of the Air Force war fighting team. It is the largest industrial complex in Georgia, employing a work force of over 25,584 civilian, contractor, and military members.

Manufacturing Excellence: Governor Locke's Speeches | Washington State Supplier Lean Training Kick-off Event

From Govenor Gary Locke, State of Washington ... ... a fine sponsor of manufacturing excellence ...

... "Raising and enhancing the skill level of manufacturing workers within all tiers of the value stream will make our suppliers even more competent. And more competitive with other states, and other countries. Strengthening our manufacturing excellence will more competitively position us to earn more manufacturing work. Including the 7E7. " ...

Lean Kaizen Training: Lean Manufacturing Workshops Help Southern Industry Compete

From Yahoo News (press release) ... Value-Stream Mapping (Nov. 30): Learn a fundamental initial step that creates the blueprint for applying other lean tools and running kaizen events. NEW! ...

Training workshops from LEI focus on how to implement key lean manufacturing tools, which will enable industry to drive operational efficiency success ...

... Regional lean manufacturing training from the nonprofit Lean Enterprise Institute (LEI), will help industry and suppliers cut costs, improve profits, and defend jobs by eliminating waste. ...

The Lean Enterprise Institute is a nonprofit training, publishing, and research organization founded by James Womack, PhD, in August 1997. It has developed simple but powerful tools for implementing a set of ideas known as lean production and lean thinking, based initially on the Toyota Production System and now extended to an entire Lean Business System.

Value Stream Map: Visteon Distribution Operations Manager Shares Insight ...

From Yahoo News (press release) ... "We view the supply chain from a total-cost perspective, starting with our own suppliers that feed parts and components into our own value stream. ...

The Visteon value stream includes all of the activities required to create a product from the suppliers parts and components and deliver into the hands of the customer. Waste is any part of the value stream process that takes time and resources but adds no value to the product ...

... Ron Huston, distribution operations manager for Visteon Corporation's (NYSE: VC) Aftermarket, spoke today at the fifth annual Autologistics Global Conference about what it takes to implement a robust aftermarket and service parts distribution strategy. ...

Visteon Corporation is a leading full-service supplier that delivers consumer-driven technology solutions to automotive manufacturers worldwide and through multiple channels within the global automotive aftermarket. Visteon has approximately 72,000 employees and a global delivery system of more than 200 technical, manufacturing, sales and service facilities located in 25 countries.

Lean Manufacturing and the Defense Industry

From RAND Corp Research Brief ... Since the end of the Cold War, the Department of Defense (DoD) has launched a number of initiatives whose common objective has been to reduce the costs of weapon systems that are planned, under development, or in production. Largely in response to these measures, U.S. defense firms have in recent years begun to embrace lean manufacturing, a broad collection of principles and practices whose aim is to refashion the production process in a manner that includes the elimination of waste, the removal of inventory buffers, and a focus on quality ...

... The results of this study clearly indicate that the integration of lean principles into military aircraft production remains in a state of flux. To be sure, nearly all manufacturers surveyed as part of this research had either implemented lean pilot projects or expressed their intention to do so. Moreover, all manufacturers who had initiated such projects reported that savings had already been derived from their efforts. At the time of this research, however, none of the manufacturers surveyed had yet implemented lean manufacturing practices on a broader scale, either from the beginning to the end of the value stream or within the factory as a whole. ...

The RAND Corporation is a nonprofit research organization providing objective analysis and effective solutions that address the challenges facing the public and private sectors around the world. For more than 50 years, the RAND Corporation has pursued its nonprofit mission by conducting research on important and complicated problems. Initially, RAND (the name of which was derived from a contraction of the term research and development) focused on issues of national security. Eventually, RAND expanded its intellectual reserves to offer insight into other areas, such as business, education health, law, and science. RAND's innovative approach to problem solving has become the benchmark for all other “think tanks” that followed.

Lean Manufacturing Training: Racine Community Bulletin Board

From Milwaukee Journal Sentinel, WI ... GATEWAY TECHNICAL COLLEGE: Offering Lean 101: Principles of Lean Manufacturing with live simulation, an eight-hour workshop, on Sept. ...

Principles of Lean Manufacturing Workshop: The real meat of the program is learning first-hand how much waste can be eliminated and about the different processes, such as Value Stream Mapping, Set-up Reduction and Cellular/Flow Manufacturing, which are all facets of becoming a lean enterprise. In fact, you’ll walk away with a solid understanding of eight key wastes in manufacturing, specifically how your business can benefit from tackling waste head-on, and what steps to take next, to further your move toward becoming lean. The workshop is taught by WMEP manufacturing specialists who have many years of real-world experience in manufacturing businesses. They understand how Lean Manufacturing can work for you, and what obstacles you will have to overcome to achieve results. Their hands-on experience makes them valuable resources for you on your road to becoming a lean manufacturer.

The Wisconsin Manufacturing Extension Partnership (WMEP) is a technical and business resource created expressly to help small and midsize manufacturers improve productivity and compete more effectively in the global marketplace. WMEP is Wisconsin’s market leader in providing high-quality, high impact solutions that deliver bottom-line improvements for manufacturers. With years of manufacturing experience, our expert staff apply effective business and manufacturing solutions that deliver measurable results. And we stay with companies through project implementation, to ensure they learn the techniques to maintain the results. Since 1996 WMEP has helped over 1300 Wisconsin manufacturers improve their productivity and profitability. Over that time WMEP customers have reported a positive impact of nearly $400 million in improvements attributable to the assistance provided by WMEP.