NAME

REG NO
CENTER
SUBJECT
TOPIC NO
TOPIC

: S.RAVINDRAN
: 211051820
: KANDY
: MEM5336
: 01
: LEAN MANUFACTURING CONCEPT

Content
1. Introduction to lean manufacturing
What is lean manufacturing
consists of Lean operating system
2. Lean principle
3. Introduction of company
4. Process map
5. Weak line areas
6. example for damage wastage
7. Detail analysis
8. Key performance indices
9. Improvement
10. Management plan
11. Conclusion

1.Introduction
What is Lean manufacturing ?
Way of eliminating waste & improve efficiency in manufacturing
Derived from Toyota production system
Focus on elimination waste, flow & value stream
Doing more with less
Definition of Lean
It is a comprehensive set of techniques which when combined
allows you to reduce and eliminate the wastes.
This will make the company leaner, more flexible and more
responsive by reducing waste.

Introduction
consists of Lean operating system
A lean operating system follows certain principles to deliver value to the
customer while minimizing all forms of loss.
Each value stream within the operating system must be optimized
individually from end to end.
Lean tools and techniques are applied selectively to eliminate the three
sources of loss: waste, variability and inflexibility.

2.Lean Principles
1. Accurately specify value from customer perspective for both products and
services.
2. Identify the value stream for products and services and remove non-valueadding waste along the value stream.
3. Make the product and services flow without interruption across the value
stream.
4. Authorize production of products and services based on the pull by the
customer.
5. Strive for perfection by constantly removing layers of waste.

3.Toyota production System

After World War II, Toyota was almost bankrupt.
Post war demand was low and minimising the cost per unit
through economies of scale was inappropriate. This led to
the development of demand-led pull systems.
The Japanese could not afford the expensive mass
production facilities of the type used in the USA so they
instead focused on reducing waste and low cost automation.
Likewise, Toyota could not afford to maintain high inventory
levels.

Toyota production System.

Founders of the Toyota Production System (TPS)

Taiichi Ohno
(1912 1990)

Shigeo
Shingo
1909 1990

4.Kinds of wastes
1. Overproduction
2. Waiting

3. Unnecessary Transport
4. Over processing
5. Excess Raw Material
6. Unnecessary Movement
7. Defects
8. Unused Employee Creativity

About the company

Penguin Sportswear
Penguin Sportswear was established in 1989 and has come a long way since. We
continue to grow in partnership with many of our customers, ensuring the Group
continues to be a leading manufacturer of high quality apparel in Sri Lanka. We
take pride in an impressive customer portfolio. Penguine Sportwear, drives its
business through its high manufacturing standards. Flexibility and Speed with
stringent quality controls and a passion to succeed, ensures total customer
satisfaction. With an experienced and dedicated workforce, our journey throughout
the years has been an eventful one. Growth and excellence has been the focus
over the years and has paid dividends by way of long standing customer
relationships. With a Vision To Create, Innovate, Excel and Delight, the Penguin
and Emjay Group will continue to excel and grow, embracing the future with an
ever evolving strength & passion.

Thank You