The top-level Lean Line Design Roadmap displays the eleven major tasks required to take your production facility from pre-Lean to fully Lean-Certified. Each of these tasks, outlined on the top-level map, is supported by a comprehensive and detailed Action Map of its own, leading you through the specific decisions and activities involved at that stage. This complete set of Lean Line Design Roadmaps will not only save you the considerable time, effort and expense in researching and preparing your Lean project, but will also serve as an invaluable checklist for getting everything done – in the right sequence and in the right way.
Assessment and Master Plan (Action Map 1.1)
Before beginning a Lean implementation, you must assess accurately your current-state processes and key metrics. Value Stream Mapping gives your team a clear picture of present issues and promising opportunities, while the Master Plan lays out the work to be done and benefits to be realized.
Data Gathering (Action Map 1.2)
The Lean Roadmap Line Design process is quantitatively-based. A well-performing flow line depends on a detailed understanding of processes, time studies, resources and the products to be built. This Action Map lays out everything you’ll need to prepare, and how to go about it.
Resource Calculations (Action Map 1.3)
The actual resources – both people and equipment – needed to achieve the desired production volume and mix are calculated from the information developed in step 1.2. Worksheets and examples are provided to illustrate the resource calculation task.
Conceptual Layout (Action Map 1.4)
A good Lean project strives to make the greatest gains possible over the current state of the facility. By focusing on just the Value-Adding activities pinpointed in the Value Stream Mapping work, your Lean team can design an optimal new Conceptual Layout, without being bound by “the way it’s always been done”.
Workstation Definition (Action Map 1.5)
With the ideal Conceptual Layout in place, the next task is to define and design each process and workstation in the Lean Line. This Action Map explains all the required steps, including how to divide and sequence the work for optimal production flow and use of resources.
Building Layout (Action Map 1.6)
Now the idealized Conceptual Layout needs to be laid out in real life – that, is, in the building you actually have available. This task, though not as tough as it might seem, typically requires hard work and problem-solving from your team, along with a few compromises. The Action Plan guides you through the crucial steps, leaving you with a detailed physical layout of the Lean Line.
Deployment Plan (Action Map 1.7)
Next comes the Deployment Plan – all the details of equipment procurement, capital budgeting, facilities improvements, the move schedule, task assignments, and project management. Laying all this out can be overwhelming, so you’ll find this Action Map particularly valuable.
Conduct Training (Action Map 1.8)
For many or most operators and supervisors, the day-to-day experience of working in a structured Lean environment may feel like quite a change. These training activities are designed to prepare everyone in the affected departments to work successfully in a Takt time-driven, flow production line.
Lean Process Live (Action Map 1.9)
Day One for a new Lean Line is an exciting and frequently daunting moment. Yet it can be the first step in a very successful transformation for your enterprise. Learn in this Action Map how to be fully prepared, and how to take the greatest possible advantage of your new Lean benefits.
Line Balancing (Action Map 1.10)
As soon as the new Lean Line is running, the Lean Roadmap moves on to a new step – immediate evaluation and adjustment of performance throughout the process. Are you finding constraints, delays, or unplanned inventory? This Action Map provides all the tools and tactics you’ll need to address issues such as these, and starts a longer-term process of Continuous Improvement.
Lean Audit and Certification (Action Map 1.11)
So, your new Lean Line has been in operation for some months, and it’s time to take a breath and assess your progress. Here’s how to measure what you’ve done and what you’ve gained, not only in crucial metrics such as volume, productivity, and inventory turns, but also in the harder-to-measure but equally important matters of employee engagement and workplace improvement. When your facility meets the new, higher standards of Lean – you’re Lean certified!
You can get this entire package for the launch price of $297.00
Payback
for this investment could literally be instantaneous, if you implement
even one or two of the suggestions included. As
with all Flow Publishing products and tools, you buy them risk-free. If
you're not satisfied you get your money back, no questions asked. Just
tell us within 30 days.
Click on "Add to Cart" to order the entire Line Design LeanRoadMap package.
This product was added to our catalog on Tuesday 16 June, 2009.
