Lean Training | Consulting Certification

5S represents five simple but powerful steps that starts with a letter “S”. The original 5S was in Japanese, but has been translated into English as follows:

Sort ( SEIRI )
Set ( SEITON )
Shine (SEISO )
Standardize (SEIKESTU )
Sustain ( SHITSUKE )

An organised workplace reduces non-value added activities of looking for information, tools and materials, and allows employees to communicate visually.

Value Stream Map (VSM) looks at the full, end-to-end process pictorially using simple icons. It is frequently use by organizations as road-map or blueprint for lean transformations.

VSM enables the visualization of how information and materials flow through all of the activities that occur from the time an order is placed, to the time the product or service is delivered.

VSM starts with customer needs, shows how and when information is received, to the end where the product or service is delivered to the customer.

Kaizen Event is a focused, intense and short-term project in which a cross-functional team makes rapid improvements in a short period of time.

An event normally takes 3 to 5 days and the intensity and urgency to take actions to solve specific issues overcomes the inertia and resistance.

Kaizen Event is a great way to show employees who are not confident about continuous improvement that they can make a difference, and can build their confidence to embark on other continuous improvement projects.

Lean is not just for the factory shopfloor. Lean is also applicable and should be implemented beyond the manufacturing floor - into the sales, admin, human resource, finance, support & other office functions.

Typical waste in an office environment includes:

- too many handoffs
- too much paper work
- unproductive but endless meetings,
- bureaucratic and unnecessary policies,
- confusing and conflicting goals,
- errors and rework

TPM aimed at maximizing equipment effectiveness through the optimization of equipment availability , performances , efficiency and product quality.

The 8 Pillars of TPM are:

1. Focus Improvement
2. Autonomous Maintenance
3. Planned Maintenance
4. Training
5. Early Equipment Managemnt( EEM)
6. Quality Maintenance
7. Efficient Administration
8. Safety & Environment

The objective of SMED is to reduce the set-up time or changeover time.

Long set-up time resulted in a reduced number of set-ups, larger batch sizes and larger buffering work-in-process inventories and poor process flow and performance.

By reducing set-up time, more set-ups can be completed each day, batch size can be correspondingly reduced, flow can be significantly improved. All these improvement will help to improve manufacturing flexibility.