1. Introduction to Lean
Presented to
Profitability in Manufacturing MEP
By Bill Bearnson

2. What is Lean Manufacturing?
Identifying what the customer wants in form fit and
function of a product. What the customer is
willing to pay for. Anything else is waste.
Systemic removal of any activity that does not add
value to the form fit or function. This is waste.
A systemic process to improving flow of a product
focusing on what adds value and the customer will
pay for.

3. What is Lean Manufacturing?
A commitment to manufacturing culture
change.
• The most noteworthy accomplishments in keeping the
price down low is the gradual shortening of production
cycles. HenryFord
• It encompasses the successful execution of all
manufacturing activities required to produce a final
product, from design engineering to delivery and
including all stages of conversion from raw material
onward. Dr. Shingo Shigeo

4. Common Wastes
1. Transport (moving products that are not actually required to perform the
processing). Example: inspection stations instead of “in process inspections”.
2. Inventory (all components, work in process, and finished product not being
processed). Example: Component failures not accounted for and reported in supplier rating.
3. Motion (people or equipment moving or walking more than is required to perform
the processing). Example solution: equipment repair done in test lab.
4. Waiting (waiting for the next production step, interruptions of production during
shift change). Example: Setup and tear down time due to parts missing or cross training.
5. Overproduction (production ahead of demand). Example: Fast food.
6. Over Processing (resulting from poor tool or product design creating activity).
Example: Design for manufacturing is missed. Test till it passes.
7. Defects (the effort involved in inspecting for and fixing defects).
Example: manufacturing assets being used for evaluating returned product revisions and failures

5. Some Lean Tools
• Five S, Kanban (pull systems)
• Value Stream Mapping: Kaizan event
• Redesigning working cells. Reducing
movement.
• Continuing improvements.
• single point scheduling. Master scheduler.

6. What is 5S?
The results you can expect from a Five S program
are: improved profitability, efficiency, service and
safety. A great place to start Lean effort

7. What’s a Kanban
and will they hurt me?
Kanban aligns inventory levels with
actual consumption.
Toyota optimized
its engineering
process by
modeling it after
supermarkets
stock shelves.
Or, Just in time.

8. Value Stream Map
Central Control.

9. Critical
Design
Review
Lean Tools
Process Flow Diagram
Engineering
Design Effort
Purchase long
lead parts
Preliminary
Design, PL and
DWG Review
Design
Released
Long lead parts
identified for
management
review.
Release long lead
P/L , preliminary
drawing and prelim
full P/L
Parts being
received
hold rack
Cycled until
full kit ready
MFG and Test/Eval &
Processing per priorities
Manufacturing
Processes document
begun and complete
Parts and Processes dropped to
manufacture floor for build and test.
Customer
Requirements
Buy LLP Decision
is a GO!!
Buy LLP Risk Decision
is Yes
TEST , MFG and
MFG MNGT
begines
involvement
Flow diagramming Benefits
1. Bring Team together
2. Team agrees on Risks and mitigation
actions
3. Cross functional review early by all
stake holders.
4. Better use of manufacturing assets.

10. Summary
Lean is:
A commitment to
manufacturing culture
change.
Lean Return on Investment:
1. Improved manufacturing
efficiency.
2. Quicker Delivery
3. On target customer wants
and needs they will pay
for.
4. Lower Cost Product.
5. Company staff retention
and moral.

11. Support

12. Lean Engineering Tools
The product design is not just based on good
design but it should be possible to produce by
manufacturing as well.
1. Design for Manufacturability
2. Robust Design with variation control

13. Lean Engineering Tools
Robust Design by variation control.
Robust parameter designs used to make visula the
interaction between control and uncontrollable
variables by robust design.
Once optimal control factors are implemented, it is
ready for production and delivery.

14. Robust Design
Example: resistor pack reduction concept
Value RF
resistors
Variable
10k-12k
RP
Gain
output
dBm
Spec’d
Circuit
Gain
.5k 10-12k 20-24dB 3-4dB
1k 10k-12k 7-10dB 3-4dB
2k 10k-12k 5-6dB 3-4dB
3k 10k-12k 3dB-4dB 3-4dB
4k 10k-12k 2-3dB 3-4dB
5k 10k-12k 2-2.4dB 3-4dB
10k 10k-12k .01-2dB 3-4dB
400 – 400KHz

15. Lean Engineering Tools
-- Design for manufacturing (DFM)
1. Simplify parts list where possible.
2. Specify parts for use, environment and possible
future environments.
3. Record risks taken in prototype stage for
addressing in first time build.
– Unavailable parts that will make the sell but don’t
meet specification completion.
– Parts that may impede manufacturing and test flow.
Note the risk and known mitigation.
4. Review for first time build and low rate build
with MFG, Design, build technicians, process
and Test.