The document provides an overview of lean operations management presented by Ayub Salik. The agenda includes defining lean manufacturing, types of waste, lean tools, a case study, challenges of lean adaptation, drivers for adopting lean, best practices for lean projects, launching a lean effort, and the role of change and performance management in lean systems. Salik then discusses his background and experience with lean projects. The presentation defines key lean concepts like value, waste, the 8 types of waste. It also reviews several lean tools and strategies like value stream mapping, line balancing, overall equipment effectiveness, cycle time.
3. OBJECTIVESOBJECTIVES
•Define lean explain its goal key principles and•Define lean, explain its goal, key principles and
techniques
G i d t di f l t h i t•Gain understanding of some lean techniques to
improving the performance effectiveness of people
and machines
•Industrial application of Lean manufacturing
5. WHO AM I AND WHAT I DO ?WHO AM I AND WHAT I DO ?
Education:
University at Albany, New York.
◦ MBA Elective Track in Management. Expected completion 2011
University at Albany, New York.
◦ MBA (ITM) 2008
◦ 2008 Graduate Academic Award Recipient. (Evening MBA)
University of Engineering and Technology, Lahore, Pakistan.
◦ B. Sc. Petroleum Engineering 1993 (First Class First)
Current Positions
Strategic Planning– Callanan Industries Inc. ( A Oldcastle Materials Company / Owned by CRH plc, Ireland)
Consultant – Glass Industry – Client: Strategic Materials Inc.
Past Positions:
Lead Change Agent – Oldcastle Materials Group (OMG) Performance System (OPS) ‐ Operations at Oldcastle Materialsg g p ( ) y ( ) p
Project Manager at Callanan Industries Inc. ( A Oldcastle Materials Company / Owned by CRH plc, Ireland)
Corporate Quality Control Manager ‐ Strategic Materials Inc. – US Region.
Plant Manger – Strategic Materials Inc , Albany NY.
Assistant Distribution Engineer ‐ Sui Northern Gas Pipelines Limited ‐ Pakistan
Reservoir Engineer ‐ Petcon Fekete Pvt. Limited (Branch of Fekete Associates Inc.‐ Canada)
Management Intern ‐ Bank of America , Union bank
Engineering Intern ‐ Schlumberger Flopetrol, Mari Gas Company
6. MY LEAN EXPERIENCEMY LEAN EXPERIENCEMY LEAN EXPERIENCEMY LEAN EXPERIENCE
Lean Management Projects :g j
New York New Jersey Massachusetts Ohio
Arkansas Oklahoma
Lean Management Trainings / Workshops :
Missouri Kansas Michigan AlabamaMissouri Kansas Michigan Alabama
Tennessee Connecticut Colorado Oklahoma
New York New Jersey Massachusetts Ohio
Arkansas Florida Georgia Texas
West Virginia
21. WHAT DO THE 8 TYPES OF WASTE MEAN ?WHAT DO THE 8 TYPES OF WASTE MEAN ?WHAT DO THE 8 TYPES OF WASTE MEAN ?WHAT DO THE 8 TYPES OF WASTE MEAN ?
5. Transportation: Any unnecessary movement of product, part or people between or
hwithin a process.
6. Rework: Performing work or service again due to defects.
7. Over processing: Processing beyond customer requirement.
8. People’s skill: Underutilizing people skills ‐ not taking advantage of the available
intellect.
28. CYCLETIMECYCLETIMECYCLETIMECYCLETIME
• Actual time to complete one cycle of anActual time to complete one cycle of an
operation; or to complete a function, job, or
task from start to finishtask from start to finish
C b d bli h h i f• Can be used to establish the capacity of a
selected piece of equipment in a specific set
f iof circumstances
36. LEAN IMPLEMENTATIONLEAN IMPLEMENTATION
DON’T S DO
Not keeping process simple
No senior management buy in
No Long term strategies
Align focus from top to down (Buy in from
the top)
Focus on the goal – eliminate waste No Long term strategies
Not showing the reason to change
to lean operations
Not involving everyone
Focus on the goal – eliminate waste
Gather baseline information using lean
tools like VSM etc. have a future state in
mind and work towards it. Not involving everyone
Ignore the change management
aspect of a lean project.
Not addressing peoples mind set
Dedicated resources
Long term strategies
Open minded and supportive teamg p p
Lack of consistency in execution Involve everyone (each level of
management)
Effectively use lean methodology (Keep it
simple)
40. USEFUL LINKS FOR LEAN SYSTEMSUSEFUL LINKS FOR LEAN SYSTEMSUSEFUL LINKS FOR LEAN SYSTEMSUSEFUL LINKS FOR LEAN SYSTEMS
• http://www.leanmanufacturingconcepts.com/LeanManufacturingBasics.zip
• http://www.strategosinc.com/just_in_time.htm
• http://www.tpslean.com/leantools.htm
• http://online.wsj.com/article/SB124933474023402611.html
• http://www2 toyota co jp/en/vision/production system/video html• http://www2.toyota.co.jp/en/vision/production_system/video.html
• http://www.toyotageorgetown.com/tps.asp
• http://www.oee.com/pdf/fast‐guide‐to‐oee.pdf
• http://operations‐extranet.mckinsey.com/html/sitetools/register.asp Register on this and p p y g p
search for
“lean”