What Is Lean Manufacturing

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What Is Lean Manufacturing

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What Is Lean Manufacturing

  1. 1. Implementation of Lean Manufacturing Evelean William BY Eng . Ahmad Bassiouny
  2. 2. <ul><li>  What is lean manufacturing? </li></ul>
  3. 3. <ul><li>Lean manufacturing is a Business philosophy that continuously shortens the time between customer order and shipment by eliminating everything that increases the cost and time. </li></ul>
  4. 4. <ul><li>Productivity improvement </li></ul><ul><li>Total Manufacturing time saved </li></ul><ul><li>Less equipment utilization (machine time, wear and tear) </li></ul><ul><li>Less scrap - material cost saved </li></ul><ul><li>Low inventory levels – stock holding cost saved </li></ul><ul><li>Quality improvement </li></ul><ul><li>Plant space saved – more efficient layout </li></ul><ul><li>Better labor utilization </li></ul><ul><li>Safety of operations </li></ul>Benefits of lean manufacturing are:
  5. 5. <ul><li>To create continuous flow with direct link between suppliers and customers </li></ul><ul><li>To use takt-times and pull-systems to manage the workflow </li></ul><ul><li>To reduce batch sizes and inventories </li></ul><ul><li>To eliminate waste </li></ul><ul><li>To cross-train workers in order to deal with inherent variability </li></ul><ul><li>Selective use of automation </li></ul><ul><li>To instill a Continuous Improvement competence </li></ul>Principles of lean manufacturing are:
  6. 6. <ul><li>Kwaliteg can help assist you with the implementation of a system that applies the principles of lean manufacturing. </li></ul>
  7. 7. <ul><li>The implementation of lean manufacturing techniques requires that all the wastes are identified and eliminated from the System. Anything that does not add value to the product can be defined as waste. Lean manufacturing aims to eliminate waste. There are different types of waste: </li></ul>
  8. 8. <ul><li>Waste of inventory (space and time) </li></ul><ul><li>Waste of Time (manufacturing time) </li></ul><ul><li>Waste of Materials (Scrap) </li></ul><ul><li>Waste of Equipment (machine time) </li></ul><ul><li>Waste of plant space and movement of materials and objects </li></ul><ul><li>Waste of Labor (unnecessary actions) </li></ul><ul><li>Waste of capital (idle times of resources) </li></ul>
  9. 9. <ul><li>Lean manufacturing is not only a project or program. It is way of thinking. </li></ul>
  10. 10. <ul><li>The implementation of lean manufacturing will comprehend the following stages: </li></ul><ul><ul><li>Data collection stage </li></ul></ul><ul><ul><li>Data analysis and development of solution Stage </li></ul></ul><ul><ul><li>Implementation Stage   </li></ul></ul>
  11. 12. <ul><li>During the Data collection stage the following activities relating to lean manufacturing are performed: </li></ul><ul><ul><li>Time studies and Motion studies </li></ul></ul><ul><ul><li>Establishment or review of Process Flow charts </li></ul></ul><ul><ul><li>Investigating Product families </li></ul></ul><ul><ul><li>Bottle necks and problem areas </li></ul></ul>
  12. 13. <ul><li>Data Collection comprehends information gathered on the current state of facilities and operations. The output will be document describing all the important facts on the current state of the facilities and operations that are relevant for lean manufacturing. </li></ul>
  13. 14. <ul><li>During the Data analysis Stage the following activities relating to lean manufacturing are performed: </li></ul><ul><li>Establishment of a Capacity plan </li></ul><ul><li>Determination of the current state of the Value Stream Map </li></ul><ul><li>Value Stream Map Future state – Micro and Macro Levels </li></ul><ul><li>Determining the Work Balance </li></ul><ul><li>Design of a Layout proposal </li></ul><ul><li>Preparation of a Project Implementation plan </li></ul>
  14. 15. <ul><li>This stage will have three documents as output: </li></ul><ul><li>Evaluation Document comprehending analysis and calculation </li></ul><ul><li>Design Document proposing a solution leading to a </li></ul><ul><li>Project implementation plan </li></ul>
  15. 16. <ul><li>During the Implementation Stage the following activities relating to lean manufacturing are performed: </li></ul><ul><li>Execution of the project implementation plan. </li></ul><ul><li>Design and manufacture of special tools and material handling equipment </li></ul><ul><li>Outsourcing of Capex (if needed) </li></ul><ul><li>Training of relevant staff </li></ul>
  16. 18. <ul><li>Kwaliteg can provide you with lean manufacturing consultants that have the relevant expertise in the field. They will perform an initial analysis, a detailed analysis and develop a solution for your organization. Assistance in the implementation and maintenance of the proposed lean manufacturing system can also be given. Additionally Kwaliteg could provide required engineering solutions as well. </li></ul>
  17. 19. <ul><li>Involvement of Kwaliteg will decrease over time . while the involvement of the Customer organization will increase . </li></ul>

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