Page 139 - How To Implement Lean Manufacturing

118 Cha pte r Se v e n

For raw materials delivery, and finished goods pickup, many facilities already have
a skeleton kanban system in place. If that is the case, teach these people the proper use
of kanban and implement kanban properly—employing all six rules.
Early on, get the planning people involved so they can begin the integration of your
planning system with the new Lean tools. They have much work to do.

Chapter Summary
The process used to make a value stream Lean consists of implementing four strategies,
which are:

• Synchronize supply to the customer, externally
• Synchronize production, internally
• Create flow
• Establish pull-demand systems

To apply the strategy, the basic diagnostic tools include:
• The takt calculation
• The basic time study and balancing analysis
• A spaghetti diagram
• Present state value stream map
• Future state value stream map
The goal is to apply the strategy, using the diagnostic tools to eliminate the seven
wastes, which are:
• Transportation
• Waiting
• Overproduction
• Defects
• Inventory
• Movement
• Excess processing

Appendix A—The Takt Calculation

Background
Takt is the rate at which a customer would pick up a product if he picked product up
uniformly during the day, while you produced it. It is the true one-piece flow, pull-
demand concept. The key waste that the takt concept strives to avoid is the waste of
overproduction, the greatest of all wastes.