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MODULE-01 Lean Overview & Matrics, Mind Map, Noureen Arshad …
MODULE-01
Lean Overview & Matrics
Main Characteristics of
Business Organizations
Goal Oriented
Organized Structure
Profit Motives
Customer Focus
Legal Identity
Continuous Activity
Use Of Resources
Decision Making
Social Responsibility
Role of Lean
in Business
Organizations
Waste Reduction
Quality Improvement
Cost Efficiency
Employee Involvement
Customer Satisfaction
Process Standardization
Continuous Improvement (Kaizen)
Flexibility
Sustainability
Fastrer Delivery
Para-time
Yesterday's Para-time
Wheel
Electricity
Today's Para-time
COVID
Artificial Intelligence (AI)
Traits Of World Class/Benchmark Companies
Toyota--Quality and Master of lean
Apple--Innovation
Amazon--customer centric
Google--Creativity
Samsung--Technology
Nike--Branding
Microsoft--Adaptability
Interloop--Sustainability,
Ethics,
Excellence
Purpose of Learning Lean
Aligns with Interloop
Vision and Mission
4E Vision
Every-ONE
Every-LEVEL
Every-DAY
Every-PROCESS
Vision 2025--To become a Full Family
Clothing Partner of Choice.
Mission--“To be an agent of positive change"
To make Interloop 1-billion company-2030
Value System
Value People
People Centric
Diversifying Business
Develop Operating
System
Differentiate/Phenomenal Services
Cost Competitive
Business Transformation
Basic ->Emerging->Leading->World Class
Lean + Six Sigma + AI
Lean--waste elimination from the processes
Six-Sigma--Identify and minimize variations in the processes
AI- Data driven automation
Learning to
see the waste
Learn to develop
Brand New Culture
The way towards creating
an Operating System
Toyota History
Origin--1937 by Kiichiro Toyoda
Toyoda Automatic Loom Works.
Early Years: Small-scale car production
& innovation in engine design.
Post-War Growth: Focusing
on quality and efficiency.
Toyota Production System (TPS) 1950:
Lean manufacturing and waste elimination.
Global Expansion:1960s–70s
with models like Corolla
Technological Innovation:
Pioneered hybrid vehicles 1997
Toyota Family
Value System
Respect for People
Continuous Improvement
Team Work
Humility
Integrity
Responsibility
Customer Focus
Four Basic Principles
Toyota Productive
System (TPS)
Just InTime(JIT)
Jidoka (Automation with a Human Touch)
Kaizen (Continuous Improvement)
Respect for People
What is Lean
Lean is a thinking System
Lean is a Mind-set
Lean is philosophy, shortens timeline b/w
requirements and delivery by eliminating waste
Lean is a systematic approach to identify &
eliminate waste through continuous improvement
by making products best quality in shortest
lead time with lowest cost
Systematic
Approach In Lean
2-Eye Calibration
to see waste
Waste:
Anything that add a cost to the product without adding any value
Forms Of Waste
MURA:
Variation situation in processes create waste
MURI:
Overburden situation create waste
MUDA:
Motion waste
Types Of Waste
TIMWOODI
I--
Inventory
M--
Motion
W--
Waiting
O--
Over-processing
D--
Defects
O--
Over-production
I--
Intelligence
T--
Transportation
3-Using tools to
Eliminate Waste
Lean Tools
a. Waste Identification Tool
(i)- Value Stream Mapping (VSM)
(ii)-Process Mapping
(iii)- Spaghetti Diagram
(iv)- Gemba
b. Waste Elimination Tools
(i)-PDCA Problem Solving (8-Step)
(ii)-5's & Visual Factory
(iii)-Total Productive Maintenance (TPM)
(iv)-Quick Change Over (QCO)
(SMED Concept)
(v)-Yamazumi (Line Balancing)
(vi)-Kanban (Material Movement)
(vii)-Poka Yoke - Error Proofing (BIQ)
(viii)-Standardize work (STW)
4-Journey of
Continuous
Improvement
1- Standardize
2- Sustain
3- Improve
1- Knowledge
Type of Works/
Activities
(ii)-Non-Value
Added Activities
Waste
Necessary but Non-Value Added
(i)-Value Added Activities
Q: How world class
organizations
are organized?
Answer: By
Applying OGSM
O--Objectives
Vision
Mission
G--Goals
Hoshin Kanri
(Policy Deployment)
HOSHIN-Direction
KANRI-Management Process
S--Strategies
Game Plan
Tactics (catalyze the strategy)
M--Measuremnts
Moral Measurement: No of Innovative ideas
Appreciation: Boost Motivation and Moral
Lean Matrices:
SQDCM
S-Safety
Q-Quality
D-Delivery
M-Morale
Lean Management
Information
Lagging Information: Already Occurred
Describes Reactive Approach
Leading Information: To Be Happened
Describes Proactive Approach
Mind Map
Noureen Arshad
Assignment-01
