Printing Lean

[KRizzo]

One of the real big issues that has been an obstruction to Lean's (TPS) progress in the Printing Industry over the last 18 years is printing management not understanding or taking on their true role in Lean.

Lean Management Basic Fundamentals

1. Everything needed for processes to perform effectively must at all times...
> Be Correct
> Function Properly
> Be Easiliy Accessible
Management can't have high expectations of people if these three issues are not done.

2. Management understanding what are X inputs and Y outputs
X Inputs are everything that is needed for a process to operate
>Man Power
>Machine
>Materials
>Methods (procedures, instructions, techniques)

Y Outputs are customers expectations from the processes
>Meet or exceed quality specifications
>Accurate amounts
>Packaging
>On time delivery
>Competitive prices

Y Outputs = the function of the X Inputs

Lean drives to perfection. If management doesn't start driving, they're not going get there.

Ken Rizzo
Printing Industries of America
Director of Consulting Services * Custom Training * Center for Lean Practices

[mattf]

Agree with you 100%. As with any process, the ability to get management "buy-in" is essential. The creation of a new mindset always is in need of management support, what I call the Authority structure:

1) Authority to oversee
2) Authority to take action
3) Authority implement
4) Authority to sustain
5) Authority to reward

Yes that was a bit fascist, but to create a structure to succeed management needs to be on board to handle the new changes and insure progress occurs.

[KRizzo]

Matt
It's not as hard as it sounds. In 1985-86 as a printing department manager, We were trained and applied TPS tools (SMED, Visual Systems, Standard Work, and 5S), before it was called Lean.
Myself and my supervisors roles were achieving everything going to the pressroom being...
>Correct
>Functioning Properly
>Easily Accessible.

It worked! It's called "Quality-at-the-Source" and it is one of the most important segments of Lean.

Ken Rizzo
Printing Industries of America
Director of Consulting services and Custom Training