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Lean Supply Chain
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Lean Supply Chain
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25 Questions

1. Procurement - Manufacturing - Warehousing - Distribution - Customers

2. Non value added time. The potential non-production time that can be eliminated from a process

3. Tools for finding the root cause: 5 Whys - brainstorming - spaghetti diagram - Pareto analysis - Cause and Effect diagrams

4. Unevenness - Rocks in the stream - hidden by inventory

5. Outsourcing - ecommerce - digitisation - globalisation - innovation - costs

6. Bringing people closer together for communication - One cell per product family - Bring together all the machines - Select appropriate tools - Aim is to have them independent - Train - balance workload - Reduce space and flow difference

7. All mfg inherently wasteful. ultimate in batch reduction is a single piece going through a process

8. The average rate at which customers buy products - and hence the rate at which products should be manufactured. actual operating time / customer requirement per shift

9. Bill of materials

10. Collaborative planning forecast replenishment -aka VMI

11. Must all work together - Suppliers - Procurement - Operations - Warehousing - Transport - Customers

12. Each step in process should be as close to Takt time as possible

13. Aligning manufacturing output with customer demand to calculate safety stocks and Kanban levels - and at the same time provide a saving to the organization by reducing the amount of money tied up in inventory

14. Value added time + nva time... time it takes to go through all the elements of a process before the activity repeats

15. The 4 ribs or bones are Man - Machine - Materials and Methods

16. Includes both va and nva activities unlike cycle time which is only the va activities. Confused by this. Processing time seems = VA activities. Process cycle is different?

17. Walk through to identify processes - Gather all relevant information - document customer/supplier info and count inventory - Establish info flow - how does each process know what to make next? - Identify push v pull - Quantify process lead time v pro

18. Rework - repair - incorrect info. Due to poor training - tools - layouts - process failures - established standards - checklists - forms. - Visual controls - 5 Whys RCA - PDCA - Poke Yoke

19. Vertical y axis stock in days - Horizontal x axis Lead time in days

20. Ship - store - move - make - pack - distribute - store - sell - return - service

21. Specific - Measurable - Achievable - Realistic - Timetable/ time based / timely

22. Buy - forecast - source - purchase - demand variability - Make - manufacture - assemble - planning - scheduling - Move - warehouse - distribution - logistics - timing - inventory - Sell - customer - demand - on-time

23. Gain corporate/top management vision - Train Lean champions/Kaizen facilitators - Access and develop the success structure - Identify the value stream - Get quick wins - Train associates and extend training to all - Engage and manage the supply chain

24. IT - Inbound logistics - Outbound logistics - Quality - Technology/design

25. Usually around 8-10%

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