Introduction

Introduction to
Lean
Manufacturing

By
Rakesh G R
 Lean Manufacturing

WHAT IS LEAN MANUFACTURING?

Lean Manufacturing can be defined as:

"A systematic approach to identifying and
eliminating waste
(non-value-added activities)
through continuous improvement by flowing
the
product through flow processes based on a
signal from the customer."
 Lean Manufacturing
Need for Lean Manufacturing

ISSUE Before Present

Economic Development Steady and linear, quite Volatile - extremely fast change,
predictable sudden downturns, and
chaotic - the direction of the
changes is not perfectly
clear

Market changes Slow and linear Fast and unpredictable

Economy Supplier-driven Customer-driven
Lifecycle of Products and Long Short
Technologies

Key Economy Drivers Large industrial firms Innovative firms

Scope of Competition Local Global hyper-competition
 Lean Manufacturing
Need for Lean Manufacturing

DEFINITION OF
WASTE

Essentially, "waste" is
anything that the
customer is not
willing to pay for.
 Lean Manufacturing
Need for Lean Manufacturing
Visible Production

We must lower the water level! Problems are Only
5% of the Total!

Machine
Breakdowns
Out-of-Spec
In-Process Workload
Materials
Inventory Imbalances
Worker Material Quality
Quality
Absenteeism Shortages Problems
Problems
 Lean Manufacturing
Steps in Lean Manufacturing

VSM
Start

 
5S,
processes

                                                                                                                         
                                                                                                                  
KPI’s
KPR’s
Understand the Current State VSD,
Kaizen

PDCA
 Lean Manufacturing

VSM – An Example

VSD – An Example
 Lean Manufacturing

Benefits of Lean
 Lean Manufacturing

Thank You