Lean Thinking Joel cutcher- Gershenfeld Senior Research Scientist, MIT Sloan School of Management and Executive Director, MIT Engineering Systems Learning Center Presentation for: 16.682 Aerospace Industry Seminar March 9 2004
Lean Thinking Joel Cutcher-Gershenfeld Senior Research Scientist, MIT Sloan School of Management and Executive Director, MIT Engineering Systems Learning Center Presentation for: 16.682 Aerospace Industry Seminar March 9, 2004
Overview Learning Objectives Session Design (60-90 Awareness of the contrast min. between“mass"and“ean” >Two mindsets (7-10 min mindsets Appreciation of the historical Historical context(10-15 context for lean thinking min. Ability to engage in lean Applications(20-30 min thinking with respect to > Implementation debate application examples (5S'S, 7 (20-30mn) Wastes, and others Concluding comments(3-5 Appreciation for the dilemmas and challenges in lean min. Implementation A visual record of where we are at in this module Mindsets→ History Applications→ Implementation> Conclusion History C Joel Cutcher-Gershenfeld MIT 3504-2
Overview ¾ Learning Objectives ¾ Session Design (60-90 ¾ Awareness of the contrast min.) between “mass” and “lean” ¾ Two mindsets (7-10 min.) mindsets ¾ Appreciation of the historical context for lean thinking ¾ Ability to engage in lean thinking with respect to application examples (5S’s, 7 ¾ Historical context (10-15 min.) ¾ Applications (20-30 min.) ¾ Implementation debate (20-30 min.) Wastes, and others) ¾ Concluding comments (3-5 ¾ Appreciation for the dilemmas min.) and challenges in lean implementation A visual record of where we are at in this module: Mindsets History Applications Implementation Conclusion © Joel Cutcher-Gershenfeld, MIT 3/5/04 -- 2
Two mindsets Mass production” Mindset“ Lean Enterprise”" Mindset Producer“push Customer“pulp Movement of materials Flow of value High volume Flexible response Inspection Prevention Expert-driven Knowledge-driven Decomposition > Integration Periodic Continuous adjustment improvement Mindsets History> Applications> Implementation Conclusion c Joel Cutcher-Gershenfeld MIT 3/504-3
Two mindsets “Mass Production” Mindset “Lean Enterprise” Mindset ¾ Producer “push” ¾ Customer “pull” ¾ Movement of materials ¾ Flow of value ¾ High volume ¾ Flexible response ¾ Inspection ¾ Prevention ¾ Expert-driven ¾ Knowledge-driven ¾ Decomposition ¾ Integration ¾ Periodic ¾ Continuous adjustment improvement Mindsets History Applications Implementation Conclusion © Joel Cutcher-Gershenfeld, MIT 3/5/04 -- 3
Where to begin? An EXercise in Lean Thinking Small groups of 2-3 people-each assigned a number >Even numbered groups > Describe a home workbench or a student dorm room used by someone engaged in"mass thinking >Odd numbered groups > Describe a home workbench or a student dorm room used by someone engaged in lean"thinking Note: An option for this exercise would be to draw a picture on a transparency to illustrate you description Mindsets History> Applications> Implementation Conclusion c Joel Cutcher-Gershenfeld MIT 3504-4
Where to begin? ¾ An Exercise in Lean Thinking: ¾Small groups of 2-3 people – each assigned a number ¾Even numbered groups: ¾Describe a home workbench or a student dorm room used by someone engaged in “mass” thinking ¾Odd numbered groups: ¾Describe a home workbench or a student dorm room used by someone engaged in “lean” thinking Note: An option for this exercise would be to draw a picture on a transparency to illustrate you description Mindsets History Applications Implementation Conclusion © Joel Cutcher-Gershenfeld, MIT 3/5/04 -- 4
Notes From Student Responses Mass Lean dorm Dorm Basic furniture -bed desk, shelf Efficient use of space -loft bed and chair under bed storage All rooms the same Combined desk Square, long halls and every floor the Aesthetic and everything within reach same Modular and reconfigurable furniture Cheapest, reliable chairs Large double pane windows Basic cleaning New, "good for you' lights Wireless internet -basic Wireless internet Workbench Workbench Excess materials stock not used, rent equipment Lots of equipment Materials ordered based on projected Storage room use Products stored in a room Quality materials and equipment More than one bench Versatile and well organized Ability to design ourselves Ability to repair our own parts Outsource to others if they would be better to do it C Joel Cutcher-Gershenfeld MIT 3504-5
Notes From Student Responses Mass ¾ Dorm ¾ Basic furniture – bed, desk, shelf, chair ¾ All rooms the same ¾ Square, long halls and every floor the same ¾ Cheapest, reliable chairs ¾ Basic cleaning ¾ Wireless internet – basic ¾ Workbench ¾ Excess materials, stock ¾ Lots of equipment ¾ Storage room ¾ Products stored in a room ¾ More than one bench © Joel Cutcher-Gershenfeld, MIT Lean ¾ Dorm ¾ Efficient use of space – loft bed and under bed storage ¾ Combined desk ¾ Aesthetic and everything within reach ¾ Modular and reconfigurable furniture ¾ Large double pane windows ¾ New, “good for you” lights ¾ Wireless internet ¾ Workbench ¾ If not used, rent equipment ¾ Materials ordered based on projected use ¾ Quality materials and equipment ¾ Versatile and well organized ¾ Ability to design ourselves ¾ Ability to repair our own parts ¾ Outsource to others if they would be better to do it 3/5/04 -- 5