Creating Basic Stability

Objectives

Creating Basic Stability focuses on making equipment stability improvements within a value stream. These problems can typically fall into categories such as availability, speed, flexibility or quality issues. The workshop will address how to identify stability related problems in the value stream, how to identify the root cause of the problems, and how to prevent them from recurring.

Creating basic stability is a critical issue for any value stream. Without a stable and reliable manufacturing process it is impossible to sustain key lean objectives such as continuous flow, level production or pull production. Toyota has spent decades perfecting its approach to establishing and maintaining production processes for fifty years. Many experts consider the topic of stability to be the place where most companies need to focus in order to begin their lean journey.

This workshop will acquaint you with the basic concepts of stability and how to improve operational reliability and availability in almost any type of facility. You’ll learn how to:

• Determine the actual line capacity and compare it to takt time
• Identify the actual bottle neck of the line
• Identify the six main types of losses in a production line
• Calculate the impact of each different loss
• Create a fact based understanding of the stability problem
• Generate root cause insights
• Create countermeasures to prevent recurrence
• Implement key maintenance concepts over the life cycle of the equipment

The benefits to achieving a more stable production process include:

• Dramatic improvement of process availability
• Reductions in scrap and rework
• Reductions in downtime
• Predictable and stable cycle times
• Improved efficiency and effectiveness of maintenance operations.