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An Overview
Dr. Richard A. Wysk
rwysk@psu.edu
http://www.engr.psu.edu/cim
Agenda
Review brief history of manufacturing
systems
Distinguish between mass, craft and lean
manufacturing
Introduce key Concepts of
Lean Manufacturing
Review the kinds of changes needed to be
considered a lean manufacturer.
Readings
Chapter 18 of Computer Aided Manufacturing, Wang,
H.P., Chang, T.C. and Wysk, R. A., 3rd Edition (2004
expected)
http://www.engr.psu.edu/cim/ie450/ie450ho1.pdf
Building the Lean Machine, Advanced Manufacturing,
January 2000.
http://www.engr.psu.edu/cim/ie450/buildingthelean.pdf
Exercise
Readiness Assessment Test
A.K.A. RAT
AS A INDIVIDUAL,
INDIVIDUAL prepare a detailed process plan
for the part shown noted in the course web page.
http://www.engr.psu.edu/cim/ie450/ie450rat.doc
Make sure the the time required to produce the part
(Process, locating and handling) is included in the plan.
This assignment will be collected in class and graded.
Exercise
Readiness Assessment Test
A.K.A. RAT
AS A TEAM (4 members),
members) take 3 minutes
to provide a written to answer the following
questions:
Were all the plans the same?
Is one better than the others?
Why?
Closed Book / Closed Notes
Objectives
To identify waste elements in a system
To apply value stream analysis to a complex
engineering/manufacturing system
To implement 3 Ms in a complex
engineering environment
To be able to identify and implement the
5Ss of lean
Craft Manufacturing
Late 1800s
Car built on blocks in the barn as workers walked
around the car.
Built by craftsmen with pride
Components hand-crafted, hand-fitted
Excellent quality
Very expensive
Few produced
Mass Manufacturing
Assembly line - Henry Ford 1920s
Low skilled labor, simplistic jobs,
no pride in work
Interchangeable parts
Lower quality
Affordably priced for the average family
Billions produced - identical
Lean Manufacturing
Cells or flexible assembly lines
Broader jobs, highly skilled
workers, proud of product
Interchangeable parts,
even more variety
Excellent quality mandatory
Costs being decreased through process improvements.
Global markets and competition.
In-class exercise
Individually, respond to the
following question (1-3
minutes)
What are the most prevalent
forms of waste in a job that
youve had or in a process
(or activity) that you are very
familiar with?
Definition of Lean
Half the hours of human effort in the factory
Half the defects in the finished product
One-third the hours of engineering effort
Half the factory space for the same output
A tenth or less of in-process inventories
Source: The Machine that Changed the World
Womack, Jones, Roos 1990
Lean Manufacturing
is a manufacturing philosophy which shortens the time line between the
customer order and the product shipment by eliminating waste.
Business as Usual
Customer
Order
Waste
Time
Lean Manufacturing
Customer
Order
Waste
Time (Shorter)
Product
Shipment
Product
Shipment
Characteristics
Fundamental change
Resources
Continuous improvement
Defined
A system which exists for the production of goods or
services, without wasting resources.
13
Definitions
Systems
Recognition
Efficiencies
Waste
Muda
7 types
Truly lean
17
Waste
Anything
Anything that
that adds
adds Cost
Cost
to
to the
the product
product
without
without adding
adding Value
Value
7 Types of Muda
7 Forms of Waste
CORRECTION
WAITING
Repair or
Rework
PROCESSING
Doing more work than
is necessary
Types
of
Waste
INVENTORY
Maintaining excess
inventory of raw matls,
parts in process, or
finished goods.
MOTION
Any wasted motion
to pick up parts or
stack parts. Also
wasted walking
OVERPRODUCTION
Producing more
than is needed
before it is needed
CONVEYANCE
Wasted effort to transport
materials, parts, or
finished goods into or
out of storage, or
between
processes.
Customer
Low Cost
High Quality
Availability
Cash
Cash !!!!
Value
Value !!!!
Your Company
Profit
Repeat Business
Growth
Waste reduction
Continuous flow
Customer pull
50, 25, 25 (80,10,10) Percent gains
22
WIP
Inventory
Space
Personnel
Product lead times
Travel
Quality, costs, delivery
23
24
25
Tools (cont.)
Continuous Flow (10% - 25%)
SMED (Shingo)
Andon
Takt time
Line balancing
Nagara (smooth production flow)
26
Tools (cont.)
Customer pull (10%- 25%)
Just-in-time
Kanban
27
Standardized Work
work sequence
job layout
time elements
safety
Other Tools
Visual Factory
Error Proofing
Quick Change-over
Total Productive Maintenance
5S Programs
31
Visual Factory
Ability to understand the status of a production area
in 5 minutes or less by simple observation without use
of computers or speaking to anyone.
5-S
1S
2S
3S
4S
5S
(Organize)
(Orderliness)
(Cleanliness)
(Adherence)
(Self-discipline)
Error Proofing
Preventing accidental errors in the
manufacturing process
Error detection
Error prevention
Exercise (3 5 minutes)
Individually, identify an area or system that
you feel lends itself to improvement using
the 5S.
What Ss can be easily applied (low
hanging fruit)?
Exercise (3 5 minutes)
As a group, discuss the recommendations
made by each group member.
Can other recommendations be made?