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Management 7
Ter m Repor t
Pr esented By:
● Fourth level
● Fifth level
VENDOR RELATIONS AND
DEVELOPMENT OF LOCAL PARTS
WELDING
● The first production process begins with
the welding department
● Semi mechanized and employs around 70
workers
● CKDs are given their very first shapes
similar to automobiles
WELDING Process
● Fourth level
● Fifth level
Key Benefits of Lean
Production
Optimize throughput
Minimize inventory
Eliminate waste (MUDA/MURI/MURA)
Flexible process design (Multi-tasking)
Pull concept (JIT)
Quality (JIDOKA/KAIZEN/ANDONS)
Doing it right the first time (KANBAN)
Partner with collaborators/suppliers
Employee empowerment
Foster the culture of continuous improvement
Key Principles of Toyota
Production System
Eliminate Waste
Wastes are all those processes that take
up production time while adding no
value to the final product. TPS focuses
on eliminating such situations or
processes that are regarded as a loop
hole in the production system and does
no good to the firm’s operations. TPS
classifies such items into three broad
categories.
MUDA
MURI
MURA
MUDA can be originated through various
bottle necks and loop holes in the system
which mainly includes, over production,
transportation, non-optimum inventory,
waiting, motion, or re-work/scrap. Any
unaddressed MUDA will nurture many other
MUDAs/MURIs/MURAs. These are
inefficiencies in any process design and
contribute in increasing costs of
manufacturing.
According to a key takeaway from our
course, inventory undergoes operations for
only 5% of the time and the rest 95% of the
time inventory is either sitting idle or its in
transit or motion.
Minimize Inventory (Small
Lot Production)
Due to the company’s focus on reducing
all the waste elements, the system
minimizes inventory and lowers the cost.
The main idea is to produce in small lots
that reduce wastage. Because large lots
often bring with them element of risk by
associating higher capital input, holding
costs, extended lead times and increased
chance of error. In contrast, small lots
minimize inventory, lower costs, improve
controls, less stocking, and assist in
achieving economies of scale.
Flexible Process Design
(Multi-tasking)
Small lot-size, efficient workforce, coherent
process and assembly designs aids in
flexible setups. These include quick
change over of internal and external
designs with respect to demand forecast
and customer requirements. The concept
is an integral part of Lean Manufacturing
and fosters the culture of training
workforce that supports multi-tasking.
Pull Concept
Wheel alignment
Brakes check
Speed check 120 km/h (drum testing)
Shower testing
Wave testing (noise checking)
CNG fitting
SQA (Shipping Quality Audit) Final
Supreme Audit
SALES PROMOTION