Lean manufacturing

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MOHAMMED AJMAL SHERIFF.F
M.TECH - MANUFACTURING ENGINEERING, B.S ABDUR RAHMAN UNIVERSITY, VANDALUR, CHENNAI

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Lean manufacturing

  1. 1. LEAN LEAN MANUFACTURING MANUFACTURING Canada Post Puts ItsStamp on a Lean TransformationMohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 1b.s.abdur rahman university.
  2. 2. Lean Manufacturing CALGARY MAIL PROCESSING PLANT •Built in 1975 •350,000 sq.ft •430 employees on three shifts daily and weekends •Processes 425 million pieces of mail annually •One of two mechanized processing plants in Alberta“I used to think that we weren’t a manufacturing company; we didn’t produceanything,”“but you can lean out mail operations. What we’re looking for is flow; in one door andout another.”said Don McLellan, director, mail operations, at the Calgary facility.Mohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 2b.s.abdur rahman university.
  3. 3. LeanManufacturing Traditional manufacturing WITH Postal operation CUSTOMER ORDER & CUSTOMER SUPPLIES RECEIVE PRODUCT MATERIAL/PRODUCT MANUFACTURING PLANT MAIL PROCESSING PLANT RAW MATERIAL END CUSTOMERMohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 3b.s.abdur rahman university.
  4. 4. LeanManufacturing Major problems • More Takt time • More Cycle time • More Conveyor system • More maintainance • Back injuries to employees • Jammed parcelsMohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 4b.s.abdur rahman university.
  5. 5. LeanManufacturing Closer Look : • Batch and Queue postal operation had many waste • Like wait time of letters and parcel to be transported and processed. • Large batches of mail require excess space, equipment and handling. • Moving mail faster doesn’t improve cash flow, but it does reduce the number of containers, forklifts and conveyors. • Waste motion. • Missorted letters of parcels are equivalent to defects and rework. • “We look more at flow because we have no control over what comes in at any point in time.” Flow between processes is maintained by FIFO (first-in, first-out) lanes., said Carli Sanderson, manager projects, at Calgary.Mohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 5b.s.abdur rahman university.
  6. 6. LeanManufacturing Four stream: • Letters • Parcels • Express mail • Publications and advertising mail “Each value stream has had success with applying lean,” said McLellan. Here’s a look at how it was done in pubs and ad mail.Mohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 6b.s.abdur rahman university.
  7. 7. LeanManufacturing Sweating the details: • Value stream Action required to bring a product from concept to Launch and from order to delivery. • Value stream mapping Previous-state map Current-state map Future-state map • Operator balance chart (OBC) • Standard Work DocumentMohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 7b.s.abdur rahman university.
  8. 8. LeanManufacturing Sample Current-state map:Mohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 8b.s.abdur rahman university.
  9. 9. LeanManufacturing Sample Current-state map:Mohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 9b.s.abdur rahman university.
  10. 10. LeanManufacturing TAKT TIME: ` Team members observed and timed operators lifting bags, reading destination tags, opening bags, dumping out the bundles of mail, reading addresses, tossing bundles of mail into containers, etc. T=24SecMohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 10b.s.abdur rahman university.
  11. 11. LeanManufacturing Operator Balance Chart (OBC):Mohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 11b.s.abdur rahman university.
  12. 12. LeanManufacturing Conveyor system:Mohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 12b.s.abdur rahman university.
  13. 13. LeanManufacturing STANDARD WORK DOCUMENT:Mohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 13b.s.abdur rahman university.
  14. 14. LeanManufacturing Lift assist arm :Mohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 14b.s.abdur rahman university.
  15. 15. LeanManufacturing Score for publications and Advertising Mail cell:Mohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 15b.s.abdur rahman university.
  16. 16. LeanManufacturing RESOLVED PROBLEMS: • 3.2 million square feet of space freed-up for consolidation, reducing reliance on leases • 10 years of consecutive profitability • Returned dividends to the Canadian government each year, including $59 million in 2005 • Reduced reliance on material handling equipment, overhead conveyors, forklifts, etc. • Dramatically reduced on-floor inventories, reducing lead time, and improving quality • Freed-up capacity and an increase in available machine time • Improved labor relations –no labor disruptions since starting lean (The company said no one would lost their employment because of lean.)Mohammed Ajmal Sheriff.Fm.Tech-manufacturing engineering. 3/10/2013 16b.s.abdur rahman university.
  17. 17. TRIP Steel Thank You Mohammed Ajmal Sheriff.F m.Tech-manufacturing engineering. 3/10/2013 17 b.s.abdur rahman university.

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