LEAN MANUFACTURING

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Lean.

Lean is completely about CULTURE, or the Thinking

Way. Introduced by Womack & Jones. Lean is a concept that centers on waste elimination . Aims to make the work simple enough to understand, to do and to manage. Improves business performance using simple, practical tools and techniques to enhance quality, cost, delivery & people contribution.
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Principles of Lean Thinking

Specify value by product: Identify customer needs, specifications and

requirements

Identify the value stream: Identify the process from product design to

sales and to satisfy the customers needs

Make the product flow: Identify the bottlenecks within the process Produce at the Pull of customer: Make the products to meet customers In pursuit of perfection (Continuous Improvement)

needs and requirements, and make it available when the customer wants it

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Aims of Organisation
To improve competitiveness To reduce wastage To improve quality

To produce faster
To reduce cost and maximize profits
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Lean Manufacturing
Management philosophy derived mostly from Toyota

Production System but also from other sources. A systematic approach to identify and eliminate waste through continuous improvement by flowing the product at the demand of the customer." Optimizing people,space,processes,activities, materials and resources.

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Continued..
Creates a culture of : Using less material Creating less waste Using less resources,water,energy etc Quality and safety Continual improvement.
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History Of Lean Manufacturing

Henry Ford introduced it during the early 20th century Toyotas Eiji Toyoda, Taiichi Ohno and Shingeo Shingo

adopted it It incorporated the Ford production process In 1990, James Womack introduced the word LEAN MANUFACTURING in his book THE MACHINE THAT CHANGED THE WORLD

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SEVEN MUDA(Deadly Waste)

The 7 Wastes
MUDA
is the Japanese word for WASTE. 5 1 4 7 3 2 6
An 8th waste is the wasted potential of people

Seek it out and get rid!

Overproduction

Over Processing
Processing beyond the standard required by the customer.

1 7

To produce sooner,faster or in greater quantities than customer demand.

Inventory

2 3

Non right first time. Repetition or correction of a process.

Rework

Raw material, work in progress or finished goods which is not having value added to it.

Waiting
People or parts that wait for a work cycle to be completed.

Transportation

Motion

Unnecessary movement of people or parts between processes. www.a2zmba.com

Unnecessary movement of people, parts or machines within a process.

Steps in Lean Manufacturing

To realize that there are wastes in the system to be

removed.
To identify the different forms of that waste & causes.
To find solutions for the identified root causes. Implementation and maintenance.

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1. Cellular Manufacturing
Reduced lead time and "in-process inventories" Simplified process flow layout Eliminating overproduction Reduced set-up and changeover times Enhanced visibility and easier identification of

problems and defects Employee involvement and empowerment

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2. Kaizen
1. Identifying the problem by going to the source / workplace.
2. Take temporary steps to solve the problem. 3. Collecting primary data to analyze and solve the problem. 4. Implement the solution and standardize work processes to prevent its future occurrence.
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3. 5 S tools

Seiri - Straighten or simplify the work area

Seiton - Sort or Simplify: Remove unnecessary items from the work area
Seiso - Scrub or Shine: Repair, clean and keep clean Seiketsu - Standardize or stabilize controls Shitsuke - Sustain or Self discipline:Strive for continuous improvement
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4. JUST IN TIME
Manufacturing and conveying
What is needed When it is needed The amount that is needed At the quality required In the shortest possible lead time

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5. Production Smoothing
Production runs take place in large batches to

minimize set-up / changeover time losses, and achieve high production efficiencies.
The process of Heijunka or smoothing synchronizes

demand with production, thus, evening out the load.

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6. Pull System
Pull system rely on the customer order pulling

material through production system when it is required.

The system can be thought of as a chain reaction,

initiated by the customer withdrawing parts.

Prevents over production

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7. Poka -Yoke
Poka:- inadvertent errors
Yokeru:- to avoid

"Mistake proofing" - preventing defective materials to

pass downstream
Poka yoke is a mechanism that prevents a mistake

from being made or makes the mistake obvious at a glance.

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