INDUSTRIAL ENGINEERING AND MANUFACTURING Cudney Edited by Elizabeth A. Cudney LEAN SYSTEMS Furterer Sandra L. Furterer Dietrich David M. Dietrich Applications and Case Studies in Manufacturing, Service, and Healthcare Lean Systems: Applications and Case Studies in Manufacturing, Service, and L Healthcare details the various Lean techniques and numerous real-world Lean projects E drawn from a wide variety of manufacturing, healthcare, and service processes, demonstrating how to apply the Lean philosophy. A The book facilitates Lean instruction by supplying interactive case studies that enable readers to apply the various Lean techniques. It provides an in-depth discussion N of the Lean tools (i.e., VSM, standard work, 5S, etc.) and several real-world case studies and applications of Lean that have shown significant improvement in meeting customer requirements. The case studies follow the Six Sigma framework of Define, Measure, Analyze, Improve, and Control (DMAIC) structure for process improvement. S The authors include detailed descriptions of each Lean tool and examples of how each Lean technique was applied to a wide variety of manufacturing, service, and Y healthcare processes. S Features • Explores the application of real-world Lean projects for each Lean technique T in manufacturing, service, and healthcare LEAN E • Provides step-by-step discussion of the Lean methodology and of each L ean technique i.e., VSM, standard work, and 5S M • Contains more than 200 figures and tables that help readers understand the Lean techniques SYSTEMS • Presents an integrated approach to Lean using the Six Sigma DMAIC methodology S • Includes downloadable software from crcpress.com that provides the templates and forms for the various Lean tools discussed in the book These in-depth descriptions and cases studies can be used by industry professionals and Applications and Case Studies academics to learn how to apply Lean. They provide a detailed, step-by-step approach to Lean and demonstrate how to integrate Lean tools for process improvement and to sustain improvements. But more than this, the approach taken in this book gives in Manufacturing, Service, readers the tools to effectively apply Lean techniques. K15438 and Healthcare 6000 Broken Sound Parkway, NW Suite 300, Boca Raton, FL 33487 711 Third Avenue New York, NY 10017 an informa business 2 Park Square, Milton Park www.crcpress.com Abingdon, Oxon OX14 4RN, UK www.crcpress.com LEAN SYSTEMS Applications and Case Studies in Manufacturing, Service, and Healthcare LEAN SYSTEMS Applications and Case Studies in Manufacturing, Service, and Healthcare Elizabeth A. Cudney Sandra L. Furterer David M. Dietrich Boca Raton London New York CRC Press is an imprint of the Taylor & Francis Group, an informa business CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2014 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Version Date: 20130516 International Standard Book Number-13: 978-1-4665-5681-2 (eBook - PDF) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmit- ted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www.copyright. com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com This book is dedicated to my husband, Brian Cudney. I am blessed to be married to an amazing, supportive, and loving husband and father. Every day, I am reminded by his words and actions that I am truly lucky to spend my life with him. Elizabeth A. Cudney I would like to dedicate this book to my husband Dan and three wonderful children, Kelly, Erik, and Zach. Sandra L. Furterer I would like to dedicate this effort to my lovely doctor wife and a specific Japanese video game manufacturer who provided hours of entertainment for my children, thereby allowing me to write the content herein. David M. Dietrich © 2008 Taylor & Francis Group, LLC Contents Preface ......................................................................................................................xi Acknowledgments ..............................................................................................xiii Editors .....................................................................................................................xv Contributors .........................................................................................................xix Section I Overview and Introduction to Lean 1 Instructional Strategies for Using This Book ...........................................3 Elizabeth A. Cudney, Sandra L. Furterer, and David M. Dietrich 2 Lean Six Sigma Roadmap Overview ..........................................................9 Sandra L. Furterer Section II Lean Tools and Step-by-Step Implementation 3 Value Stream Mapping ................................................................................65 Elizabeth A. Cudney 4 Using 5S and Visual Management to Create a Clean and Manageable Work Environment ................................................................81 Elizabeth A. Cudney 5 Using Single-Minute Exchange of Dies and Total Productive Maintenance to Reduce Setup Time and Downtime ............................93 Elizabeth A. Cudney 6 Flow, Pull, and Kanban .............................................................................111 Elizabeth A. Cudney 7 Mistake Proofing (aka P oka-Yoke): Preventing Defects by Monitoring Process Conditions and Correcting Errors at the Source ............................................................................................................125 Elizabeth A. Cudney 8 Standard Work: Documenting the Interaction between People and Their Environment .............................................................................135 Elizabeth A. Cudney © 2008 Taylor & Francis Group, LLC vii viii Contents 9 Systems Thinking and Theory of Constraints .....................................155 Elizabeth A. Cudney, David M. Dietrich, and Sandra L. Furterer 10 Hoshin Kanri ...............................................................................................161 Elizabeth A. Cudney Section III Manufacturing, Service, and Healthcare Case Studies 11 Lean Restaurant ..........................................................................................185 Corbin LeGrand, Neha Pawar, Snehal Digraskar, Sneha Mahajan, Sukhada Mishra, and Susan Polson 12 Achieving Flow in a Rapid Prototyping Laboratory ...........................203 Shirish Sreedharan, Elizabeth A. Cudney, and Frank Liou 13 Implementing Lean Manufacturing Techniques to Achieve Six Sigma ......................................................................................................213 Elizabeth A. Cudney 14 Pump Teardown Review Process Improvement ..................................229 Shrey Arora and Rodney Ewing 15 Improving Women’s Healthcare Center Service Processes ...............255 Sandra L. Furterer 16 Application of Lean Tools in a Medical Device Company .................279 Kelly M. Davis, Elizabeth A. Cudney, and Scott E. Grasman 17 Motor Grader Assembly Line Modification ..........................................291 Mujahid Abjul, Charlie Barclay, Nanday K. Dey, Amita Ghanekar, and Lynda Melgarejo 18 Sunshine High School Discipline Process Improvement: A Lean Six Sigma Case Study ................................................................................315 Marcela Bernardinez, Khalid Buradha, Kevin S. Cochie, Jose Saenz, and Sandra L. Furterer 19 Financial Services Improvement in a City Government: A Lean Six Sigma Case Study ................................................................................377 Sandra L. Furterer © 2008 Taylor & Francis Group, LLC Contents ix 20 Application of Lean Tools in a Hospital Pharmacy .............................409 Seth Langston, Jason Park, and Raj Vemulapally 21 Using Value Stream Mapping to Identify Performance Gaps for Hoshin Planning .........................................................................................433 Elizabeth A. Cudney Section IV Planning and Implementation Strategies for Lean Initiatives 22 Planning and Executing a Kaizen Workshop .......................................447 David M. Dietrich 23 Prioritizing the Lean Initiatives ..............................................................457 Sandra L. Furterer 24 Emerging Technologies Influencing Lean .............................................475 David M. Dietrich, Elizabeth A. Cudney, and Sandra L. Furterer 25 Future and Challenges of Lean: Engagement and Success Factors ..483 Elizabeth A. Cudney and Sandra L. Furterer Glossary ...............................................................................................................491 © 2008 Taylor & Francis Group, LLC