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Swati Singh
Lean Manufacturing
Presentation by
Ashutosh Trivedi
Asma Tahir Avinash Narang Astha Saxena
LEAN MANUFACTURING
Lean manufacturing focuses on reducing waste.
The concept of Lean Manufacturing was developed by
TYPES OF WASTE
OVERPRODUCTION
INVENTORY MOTION WAITING TRANSPORTATION RE-WORK OVER-PROCESSING
design
based flow manufacturing. In this type of production setting, inventory is only pulled through each production center when it is needed to meet a customers order.
1) decreased cycle time 2) increased productivity
3) less inventory
4) increased capital equipment utilization
product and process improvement and the elimination of non-value added activities.
Lean Manufacturing Methods creative and innovative approaches to analysis and design through the implementation of lean manufacturing methods.
use of the kanban significantly lowers waste and enhances productivity on the factory floor. In addition to eliminating waste, lean manufacturing seeks to provide optimum quality by building in a method whereby each part is examined immediately after manufacture, and if there is a defect, the production line stops so that the problem can be detected at the earliest possible time.
lots on a daily basis, and machines are not necessarily run at full capacity.
creative and innovative approaches to analysis and design
to provide optimum quality by a method whereby each part is examined immediately after manufacture.
stockpiles of inventory in strategic locations around the assembly line, instead of in centralized warehouses.
The concept of lean is to simply eliminate waste
Low inventory
Quality improvement Plant space saved
automobile business, developed the concept of Just-in-Time in the 1930s. He decreed that Toyota operations would contain no excess inventory and that Toyota would strive to work in partnership with suppliers to level production.
Taiichi Ohno, Toyota's chief of production in the post-WWII
Motor Corporation to provide best quality, lowest cost, and shortest lead time through the elimination of waste. TPS is comprised of two pillars, Just-in-Time and Jidoka (autonomation). TPS is maintained and improved through iterations of standardized work and kaizen (continuous improvement), following PlanDo-Check-Act (PDCA Cycle from Dr. Deming), or the scientific method.
Define value from the perspective of the final customer. Express value in terms of a specific product, which meets the customer's needs at a specific price and at a specific time.
Step 2: Value Stream Mapping.
Identify the value stream, the set of all specific actions required to bring a specific product through the three critical management tasks of any business: the problem-solving task, the information management task, and the physical transformation task. Create a map of the Current State and the Future State of the value stream. Identify and categorize waste in the Current State, and eliminate it!
Make the remaining steps in the value stream flow. Eliminate functional barriers and develop a product-focused organization that dramatically improves lead-time.
Step 4: Create Pull Production
There is no end to the process of reducing effort, time, space, cost, and mistakes. Return to the first step and begin the next lean transformation, offering a product which is ever more nearly what the customer wants.
TOYOTAS PHILOSOPHY
Selling price Cost = Profit Customers decide the selling price. Profit is what remains after subtracting the cost from it. The main way to increase profit is to reduce cost. Consequently, cost reduction through waste elimination should have the highest priority. Toyotas paradox: Reducing cost (waste), will reduce lead time while increasing quality and customer satisfaction.
Traditional Flow
Suppliers
Customers
Inventory (stagnant ponds) Material (water in stream)
Customers
Thank You