Lean Manufacturing

The development and implementation of lean manufacturing techniques is a major element of our work at Design Systems, Inc. We view lean manufacturing as the single most powerful tool for improving the capability of companies to react quickly to changing markets and stay ahead of the competition. Lean manufacturing is many things to many people, yet at it's core is the driving factor to eliminate waste and non-value added activities from your process. It will impact every process on the production floor and will impact the throughput capability of your facility. Design Systems is a leading provider of lean solutions and will help you get your manufacturing process lean..

Lean Manufacturing Overview

Lean manufacturing means many things to different people. Sure in concept it is easy - identify, categorize, and eliminate waste Waste can traditionally be classified under 3 major catergories in Lean manufacturing according to Taiichi Ohno. The first category is MUDA also known as the original seven wastes – Transportation (excess movement of products), Inventory (decrease WIP and finished product), Motion (people or equipment non-value added), Waiting (for the next production step), Overproduction (production ahead of demand), Over Processing (due to poor tool or product design), and Defects (excess effort required for inspecting and repairing defects). The next of the three categories is Mura which is the concept of utilizing JIT (Just in Time) inventory management by supplying the production process with the right part, at the right time, in the right amount, and first-in, first-out (FIFO) component flow. This is accomplished by create one piece flow, pull systems, a Plan for Every Part (PFEP) and minimizing sub assembly WIP. The last major category is Muri which is the overburden of the operator. This is most commonly resolved by the implementation of standarized work, creating a repeatable process, a logical work flow, and establishing a Takt time for the operators.

Too many companies will come in, teach you the principles, and tell you good luck.  You could spend thousands of dollars learning theories from "lean experts" with no practical experience.  DSI engineers use lean principles in every aspect of what they do.  We don’t just come in and tell you what you should do, we are part of a team that follows through the planning phase, through the tryout phase, and stick around for the execution phase so that we can validate the changes and continuously improve our own approach.  Lean tools need to be applied differently based on the requirements of your specific application.  The same principles for non value added walk are applied much differently in a 150 piece production line than a 2 piece per day job shop.  No matter how big or small your facility, no matter what they application, we will work with you to create the best business case customized to your needs.

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Standardized Work Assignments

Standardized work has been around since Henry Ford so what is so different about the concept in regards to Lean Manufacturing?  What is the best way to get the hourly employees involved in the process?

The key to standardized work is empowering the worker.  DSI has created very simple to use forms which any worker can easily learn, understand, and maintain once we are gone.  We have customized forms to fulfill the requirements for stop stations, job shop applications, and for typical assembly line process work.

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5S Applications

Organizing your workplace is the first place to start with any lean manufacturing environment.  Keeping it organized is a whole different battle.  What tools do you need?  How do you empower the worker to maintain a clean, safe, organized work environment?

DSI has managed programs to custom design the tools you need to maintain a world class 5S workstation.  From ordering the cabinets to creating the schedule and assignments for the various team members to maintain a clear workstation we have the tools and expertise.  As with everything that DSI does we don’t just sell you some tools and walk away, we will work with you through the implementation phase of lean manufacturing to assure that 5S becomes a way of live, not just another passing fad.

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Value Stream Mapping / Process Mapping

Organizing your workplace is the first place to start with any lean manufacturing environment.  Keeping it organized is a whole different battle.  What tools do you need?  How do you empower the worker to maintain a clean, safe, organized work environment?

DSI has managed programs to custom design the tools you need to maintain a world class 5S workstation.  From ordering the cabinets to creating the schedule and assignments for the various team members to maintain a clear workstation we have the tools and expertise.  As with everything that DSI does we don’t just sell you some tools and walk away, we will work with you through the implementation phase of lean manufacturing to assure that 5S becomes a way of live, not just another passing fad.

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Kaizen Workshop / Continuous Improvement / Team Building

If you always do what you have always done you will always get what you have always got.  Everyone knows this saying but how do you break out of that mode?  Yesterday’s solutions don’t always work today, and you may have never seen tomorrow’s problems before.  So how do you bring the discipline to your team to help them solve their own problems with focus on continuous improvement?

DSI has chaired Kaizen workshops for all types of organizations.  We have met with direct operators on the line to discuss the problem and walk through solutions with fish bone diagrams and PDCA (Plan, Do, Check, Act) forms to give them the tools to be successful.  By doing this we can help develop a culture of continual small continuous improvement that will significantly improve the morale of the workers and the bottom line for upper management.  We have chaired workshops with engineering teams and upper plant management to determine the best means for solving larger scale problems.  No matter how big or small the team, the opportunities for improvement can always be found with the right approach!

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Yamazumi Charts / Line Balancing

If you always do what you have always done you will always get what you have always got.  Everyone knows this saying but how do you break out of that mode?  Yesterday’s solutions don’t always work today, and you may have never seen tomorrow’s problems before.  So how do you bring the discipline to your team to help them solve their own problems with focus on continuous improvement?

DSI has chaired Kaizen workshops for all types of organizations.  We have met with direct operators on the line to discuss the problem and walk through solutions with fish bone diagrams and PDCA (Plan, Do, Check, Act) forms to give them the tools to be successful.  By doing this we can help develop a culture of continual small continuous improvement that will significantly improve the morale of the workers and the bottom line for upper management.  We have chaired workshops with engineering teams and upper plant management to determine the best means for solving larger scale problems.  No matter how big or small the team, the opportunities for improvement can always be found with the right approach!

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Techniques and Methods

• Standardized Work (MOST and Modapts certified)

  Line balancing (Yamazumi), Design out overburden (Muri) and inconsistency (Mura), Team concept, Improved quality, and Reduce non-value added walk

• Kaizen Workshops

  Team involvement for problem solving and Waste elimination (Muda)

• Fork Free

  Flexible manufacturing, Level demand, Minomi, Automation interface (Jidoka), and Improved safety

• Visual Management

  5S Signage, Labels, Foot printing, and EMP (Poka-yoke)

• One-Piece Flow

  Just in Time, Inventory management, Supply chain optimization, and Plan for every part (Kanban)

• Value Stream Mapping

  Process evaluation, Waste elimination (Muda), and Optimization

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Manufacturing and Industrial Gallery