Lean Manufacturing Systems

  1. The Five Principles of Lean Thinking
    1. Principle 1: Specify Value
      1. Customer Value Definition
        1. External Customer Requirements
          1. Internal Customer Needs
            1. Value Specification Methods
            2. Activity Classification
              1. Value-Added Activities
                1. Non-Value-Added but Necessary Activities
                  1. Pure Waste Activities
                  2. Value Analysis Techniques
                    1. Customer Interviews
                      1. Market Research
                        1. Voice of Customer Methods
                      2. Principle 2: Map the Value Stream
                        1. Value Stream Identification
                          1. Process Boundaries
                            1. Information Flow
                              1. Material Flow
                                1. Timeline Mapping
                                2. Current State Mapping
                                  1. Data Collection Methods
                                    1. Process Documentation
                                      1. Waste Identification
                                        1. Bottleneck Analysis
                                        2. Future State Design
                                          1. Improvement Opportunities
                                            1. Flow Optimization
                                              1. Waste Elimination Planning
                                                1. Implementation Roadmap
                                              2. Principle 3: Create Flow
                                                1. Flow Fundamentals
                                                  1. Continuous Flow Principles
                                                    1. Batch Size Reduction
                                                      1. Single-Piece Flow
                                                        1. Flow Interruption Elimination
                                                        2. Process Design for Flow
                                                          1. Line Balancing
                                                            1. Process Synchronization
                                                              1. Layout Optimization
                                                                1. Capacity Planning
                                                                2. Flow Implementation
                                                                  1. Cell Design
                                                                    1. Equipment Arrangement
                                                                      1. Operator Training
                                                                        1. Flow Metrics
                                                                      2. Principle 4: Establish Pull
                                                                        1. Pull System Fundamentals
                                                                          1. Customer Demand Driven Production
                                                                            1. Pull vs Push Comparison
                                                                              1. Pull System Benefits
                                                                                1. Implementation Requirements
                                                                                2. Pull System Mechanics
                                                                                  1. Kanban Implementation
                                                                                    1. Signal Systems
                                                                                      1. Replenishment Rules
                                                                                        1. Inventory Management
                                                                                        2. Pull System Design
                                                                                          1. System Architecture
                                                                                            1. Control Points
                                                                                              1. Buffer Management
                                                                                                1. Performance Monitoring
                                                                                              2. Principle 5: Pursue Perfection
                                                                                                1. Continuous Improvement Philosophy
                                                                                                  1. Perfection as Journey
                                                                                                    1. Incremental Improvement
                                                                                                      1. Breakthrough Improvement
                                                                                                        1. Improvement Culture
                                                                                                        2. Organizational Engagement
                                                                                                          1. Employee Involvement
                                                                                                            1. Management Commitment
                                                                                                              1. Cross-Functional Teams
                                                                                                                1. Improvement Suggestions
                                                                                                                2. Standardization and Evolution
                                                                                                                  1. Standard Work Development
                                                                                                                    1. Best Practice Capture
                                                                                                                      1. Iterative Improvement
                                                                                                                        1. Knowledge Management

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                                                                                                                    1. Introduction to Lean Manufacturing

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                                                                                                                    3. The Pillars of the Toyota Production System