Lean Manufacturing

PRESENTED BY SUSHEEL DUBEY(10) ASIYA SHAIKH(32) MIHIR JANI()

Definition of Lean Manufacturing

Lean manufacturing is a comprehensive term referring to manufacturing methodologies based on maximizing value and minimizing waste in the manufacturing process. Value is defined as an item or feature for which a customer is willing to pay. All other aspects of the manufacturing process are deemed waste. Lean manufacturing is used as a tool to focus resources and energies on producing the value-added features while identifying and eliminating non value added activities.

Goals of Lean Manufacturing

Get ever closer to zero
Zero

waste Zero defects Zero scrap Zero rework Zero receiving rejections Zero downtime Zero inventory Zero handling Zero paperwork Zero mistakes

Get ever closer to zero process times

Setups Sales quotes Delivery date promising Sales order delivery Production process time Purchase order lead times Outsourcing Engineering changes Time to market Returns Repairs Data collection Data analysis

Origin Of Lean Manufacturing

The Industrial Revolution marked the emergence of lean thinking in operational practices, such as standardization of methods and materials, interchangeability of parts, specialization of labor, large batch operations, and dedicated machinery. These operational practices were used only in manufacturing processes for high-volume products. Henry Ford provided the first industrial firm that had traces of lean manufacturing (main assembly line and key subassemblies). Originally a Japanese methodology known as the Toyota Production System designed by Sakichi Toyoda, lean manufacturing centers around placing small stockpiles of inventory in strategic locations around the assembly line, instead of in centralized warehouses. These small stockpiles are known as kanban, and the use of the kanban significantly lowers waste and enhances productivity on the factory floor.

Mass Production Vs. Lean Production

General Motors 40.7 31 130 8.1 2 wk Toyota 18 16 45 4.8 2 hr

Gross assembly hours per car Adjusted assembly hours per car Assembly defects per 100 cars Assembly space per car (sq. ft) Inventories of parts

Waste associated with Mass Production

Over-Production Waste Fixing Defects Waste Unnecessary Motion Waste Inventory Waste Over-Processing Waste Transportation Waste Waiting Waste

Steps to reduce or eliminate waste Lean Manufacturing

Organize the workplace (5S) Arrange everything to flow Make small batches (ideal lot size is 1) Introduce pull systems (self-correcting control) Never stop continuous improvement

Traditional Organization Employees Scheduling Production Maintenance Quality Control Complex, functional departments Individuals Forecasts Push, batch, big lot Reactive

World Class Lean Simple, product focused Teams Actual demand Pull, flow, small lot Proactive

Detection & correction Prevention Reports, supervision, blame-oriented Visual Scorecards, teams, goal-oriented

Relationship Between Lean and Six Sigma

Important point for companies is to first determine goal, and then adopt and apply the appropriate strategy in order to achieve the goal.

Lean
Waste

Initiative Tactical Objectives Improvement Project Characteristic

Six Sigma
Variation

elimination Work concentration Flow

reduction Rework & scrap elimination Process Control

Process-based Reduce Cycle time

Product-based Improve Quality

Goal

Why is Lean Manufacturing Important?

Many companies have turned to lean techniques as a way to achieve lower costs and more factory throughput. The most progressive companies, seeing the astonishing success that lean provides on the shop floor, have begun to apply lean methods to the entire supply chain. Companies that understand the evolving enterprise know that every step in the supply chain, even those that occur at the customer or supplier, has to be examined using lean techniques in order to achieve the maximum benefits. These companies find that they not only survive in difficult times, but they actually thrive and gain market share as their competition falls behind.

How does Lean affect Project Management?

As interest in lean production grows, this vocabulary engineering is also accompanied by scope creep: what started out with a focus on the factory expands to cover product design, office work, distribution, and services. And new terms follow: Lean Management Lean Enterprise Lean Thinking Lean Performance Project Management Lean Product Development

QUESTION

???????????????????????????????????????????????????? ???????????????????????????????????????????????????? ???????????????????????????????????????????????????? ???????????????????????????????????????????????????? ???????????????????????????????????????????????????? ???????????????????????????????????????????????????? ???????????????????????????????????????????????????? ???????????????????????????????????????????????????? ???????????????????????????????????????????????????? ????????????????????????????????????????????????????

THANK YOU