Lean production-system


Published on

In this Presentation you find Different Production System.Like Japan,America

Published in: Business, Technology
No Downloads
Total views
On SlideShare
From Embeds
Number of Embeds
Embeds 0
No embeds

No notes for slide

Lean production-system

  1. 2. <ul><li>A Brief History of Car Manufacturing </li></ul><ul><ul><li>Invention of Automobile in 1880 </li></ul></ul><ul><ul><li>The Henry Ford Mass Production System </li></ul></ul><ul><ul><li>The Toyota or Lean Production System </li></ul></ul>Toyota Production System
  2. 3. <ul><li>Invention of Automobile </li></ul><ul><li>Carl Benz is generally given credit to develop world first automobile in 1985 </li></ul><ul><li>Gotlib Daimler is also contemporary of Carl Benz who is simultaneously developed the automobile with him. </li></ul><ul><li>Other contemporaries are Wilhelm Maybach and Seigfried Marcus known for developing automobile later during the same period. </li></ul>Toyota Production System Carl Benze Gotlib Daimler
  3. 4. Toyota Production System Carl Benze Gotlib Daimler Replica of the Benz Patent Motorwagen built in 1886
  4. 5. Toyota Production System Carl Benze Gotlib Daimler Carl Benze First Motorcyle
  5. 6. Toyota Production System Carl Benze Gotlib Daimler
  6. 7. Toyota Production System Carl Benze Gotlib Daimler Carl Benze “Vilo” Model of 1894
  7. 8. <ul><li>Henry Ford’s Mass Production System </li></ul><ul><li>In 1910 Henry Ford laid the foundation of first highly organized assembly line system of automobile manufacturing. </li></ul><ul><li>He organized all the elements of a manufacturing system-- people, machines, tooling, and products-- and arranged them in a continuous system called conveyer system for manufacturing the Model-T automobile. </li></ul><ul><li>Ford was so incredibly successful he quickly became one of the world's richest men and put the world on wheels. </li></ul><ul><li>Ford Motor Company produced “A-Bomber an Hour” during WWII for USAF using the same concept. </li></ul>Toyota Production System
  8. 9. <ul><li>Ford Motor Company’s Production Lines </li></ul>Toyota Production System
  9. 10. <ul><li>Henry Ford Introduced Conveyer Belt System in Automotive Industry </li></ul>Toyota Production System
  10. 11. <ul><li>A bomber an hour: Assembly in Ford Motor Company </li></ul><ul><li>B-24 bomber final assembly area at Ford Motor Company's Willow Run plant </li></ul>Toyota Production System
  11. 12. <ul><li>Toyoda Family in Auto Industry </li></ul><ul><li>The Allied victory and the massive quantities of material behind it (“A Bomber an Hour” success) caught the attention of Japanese industrialists. </li></ul><ul><li>Toyoda family were among those Japanese industrialists who were observing American industrial strength and wanted to emulate it by investing in Automotive Industry. </li></ul><ul><li>Toyoda Automatic Loom Company, under the encouragement of the Japanese government, which needed domestic vehicle production partly due to the worldwide money shortage and partly due to the war with China </li></ul><ul><li>The Toyota Motor Corporation was founded in September 1933 when Toyoda Automatic Loom created a new division devoted to the production of automobiles under the direction of the founder's son, Kiichiro Toyoda. </li></ul>Toyota Production System Kiichiro Toyoda The first production model AA in 1936
  12. 13. <ul><li>Toyota Learns From the Ford Motor Company </li></ul><ul><li>Toyota found it difficult to emulate Ford Motor Company whose production system was based on Mass Production System. </li></ul><ul><li>Post WWII Japanese economy was in shambles and Toyota could not afford Mass Production of vehicles due to smaller market size. </li></ul><ul><li>Toyota’s top bosses begin to design a whole new concept of Production System which is now also known as Just-in-Time system. </li></ul>Toyota Production System
  13. 14. <ul><li>At Toyota Motor Company, Taichii Ohno and  Shigeo Shingo , are known as the brain behind transforming Ford production  and other techniques into an approach called Toyota Production System or Lean Production System or Just-in-Time System. </li></ul><ul><li>Taichii Ohno was the Production Boss of Toyota Motor Corporation and Shigeo Shigo was industrial engineer and consultant of Toyota Motor Corporation. </li></ul>Toyota Production System Taichii Ohno Shigeo Shingo
  14. 15. <ul><li>Ford vs. Toyota model of Production System </li></ul><ul><li>Can be best explained as: </li></ul><ul><li>Mass Production vs. Lean (JIT) Production </li></ul>Toyota Production System
  15. 16. <ul><li>What is Mass Production System </li></ul><ul><li>Mass production is the name given to the method of producing goods in large quantities at low cost per unit. </li></ul><ul><li>This system of production is also known as Push System or Just-in-Case System. </li></ul><ul><li>To make it worthwhile, mass production requires mass consumption. </li></ul><ul><li>With precision equipment, large numbers of identical parts could be produced at low cost and with a small work force. </li></ul>Toyota Production System
  16. 17. <ul><li>What is Lean Production System? </li></ul><ul><li>Lean Production System is the system designed and evolved in Toyota Motor Corporation. </li></ul><ul><li>It is the modified form of Henry Fords Mass Production System. In some areas its philosophy seem exactly opposite to the fundamental principles of Mass Production System. </li></ul><ul><li>This system is generally known as JIT system, which in fact is an important pillar of Lean Production System. </li></ul><ul><li>The slogan of Lean Production is “Less is best” </li></ul>Toyota Production System
  17. 18. Toyota Production System Toyota Production System <ul><li>Just-in-Time </li></ul><ul><li>Leveled Production </li></ul><ul><li>Pull System </li></ul><ul><li>Continuous Flow </li></ul><ul><li>Processing </li></ul><ul><li>Takt Time </li></ul><ul><li>Flexible Work Force </li></ul><ul><li>3 Ms </li></ul><ul><li>5 S </li></ul>Standardized Work Kaizen (Continuous Improvement) <ul><li>Jidoka (Automation) </li></ul><ul><li>Andon- Fixed Position Stop </li></ul><ul><li>System </li></ul><ul><li>Pokayoke- Fail Proofing </li></ul><ul><li> System </li></ul>
  18. 19. <ul><li>Just-in-Time (JIT) System </li></ul><ul><li>Just-in-Time means PRODUCING: </li></ul><ul><li>a) Only what is needed </li></ul><ul><li>b) in necessary quantity </li></ul><ul><li>c) at necessary time </li></ul>Toyota Production System
  19. 20. <ul><li>Main Components of JIT </li></ul><ul><li>Leveled Production </li></ul><ul><li>Pull System </li></ul><ul><li>Continuous Flow Processing </li></ul><ul><li>Takt Time </li></ul><ul><li>Flexible Workforce (Shojinka) </li></ul><ul><li>3 Ms </li></ul><ul><li>5 S </li></ul>Toyota Production System
  20. 21. <ul><li>Leveled Production means producing various model variations on the same line to cater the customer demand </li></ul>Toyota Production System Conveyer Belt
  21. 22. <ul><li>Leveled Production-Flexible Production Line </li></ul>Toyota Production System
  22. 23. <ul><li>Pull System (Don’t Push) </li></ul><ul><li>Produce only when your customer demands the product in the required quantity. </li></ul><ul><li>Run the production according to this demand </li></ul>Toyota Production System
  23. 24. <ul><li>Pull System or Kanban System? </li></ul>Toyota Production System
  24. 25. Toyota Production System
  25. 26. <ul><li>Continuous Flow Production </li></ul><ul><li>In TPS it means arranging work inside each process to flow smoothly from one step to other </li></ul>Toyota Production System
  26. 27. Toyota Production System Process A Process C Process B Just-in-Case (JIC) Involves the use of buffer or safety stock Buffer or Safety Stock Buffer or Safety Stock
  27. 28. Toyota Production System Process A Process C Process B
  28. 29. Toyota Production System Process A Process C Process B
  29. 30. Toyota Production System Process A Process C Process B
  30. 31. Toyota Production System Process A Process C Process B
  31. 32. Toyota Production System Process A Process C Process B Defect detected at Process B that actually occurred at Process A
  32. 33. Toyota Production System Process A Process B Process C Smooth Flow Processing
  33. 34. Toyota Production System Process A Process B Process C Smooth Flow Processing Defect is detected and countermeasures are taken immediately
  34. 35. <ul><li>Takt Time : Takt is a German word meaning “meter”. </li></ul><ul><li>It is the time to finish a given amount of work-doing a single operation, making one component, or assembling an entire car. </li></ul>Toyota Production System Takt time = Total daily operating time Total production requirement Takt time = 480 100 = 4.8 min/ vehicle
  35. 36. <ul><li>Flexible Workforce (Shojinka) </li></ul><ul><li>Flexible workforce or shojinka means to alter (decrease or increase) the number of operators within a shop, to equip with demand changes. </li></ul>Toyota Production System
  36. 37. <ul><li>Multi-machine Handling </li></ul>Toyota Production System Type of Part A B C D Machine (Lathing) 1 Machine (Milling) 2 Machine (Drilling) 3 Machine (Tapping) 4 One person handles one process, four machines Unfinished Parts Finished Products
  37. 38. <ul><li>Multi-process Handling </li></ul>Toyota Production System Type of Part A B C D Machine (Lathing) 1 Machine (Milling) 2 Machine (Drilling) 3 Machine (Tapping) 4 One person handles four processes, four machines
  38. 39. <ul><li>3 M ’s </li></ul><ul><li>M UDA = Non-Value Added </li></ul><ul><li>M URA = Overburden </li></ul><ul><li>M URI = Unevenness </li></ul>Toyota Production System
  39. 40. Toyota Production System 1 TON 4 ton Capacity : 4 tons Muda . Mura . Muri 12 TONS
  40. 41. Toyota Production System X X 2 = MURI (OVERBURDEN) 6 = MUDA (NON-VALUE ADDED) = MURA (UNEVENNESS)
  41. 42. <ul><li>The most efficient way to deliver 12 tons of good to the destination is: </li></ul>Toyota Production System X 3 = NO MURI (OVERBURDEN) NO MUDA (NO WASTAGE) NO MURA (NO UNEVENNESS)
  42. 43. Toyota Production System 5 S <ul><li>S EIRI = S IFTING </li></ul><ul><li>S EITON = S ORTING </li></ul><ul><li>S EISO = S WEEPING </li></ul><ul><li>S EIKETSU = S PICK ‘N’ SPAN </li></ul><ul><li>S HITSUKE = S USTAINANCE </li></ul>
  43. 44. <ul><li>SEIRI = SIFTING </li></ul><ul><li>Get rid off unwanted stuff from the workplace </li></ul>Toyota Production System TRASH Unwanted
  44. 45. <ul><li>SEIRI = SIFTING </li></ul>Toyota Production System
  45. 46. <ul><li>SIETON = SORTING </li></ul><ul><li>Arranging wanted items in proper order, which means place for every thing and every thing in its place. </li></ul>Toyota Production System Boxes staked well sorted and orderly manner Disorderly staking
  46. 47. <ul><li>SIETON = SORTING </li></ul>Toyota Production System
  47. 48. <ul><li>SIETON = SORTING </li></ul>Toyota Production System
  48. 49. <ul><li>SIESO = SWEEPING AND CLEANING </li></ul><ul><li>Sweeping and cleaning means surface and other areas free from oil and chemicals that may or may not cause slippage, fire or any other possible hazard. </li></ul>Toyota Production System
  49. 50. <ul><li>SEIKETSU = SPICK ‘N’ SPAN </li></ul>Toyota Production System Spick ‘n’ span means visible neatness. A nice, clean and tidy workplace Affects directly to the performance and quality of workforce.
  50. 51. <ul><li>SEIKETSU = SPICK ‘N’ SPAN </li></ul>Toyota Production System
  51. 52. <ul><li>SHITSUKE = SUSTAINANCE </li></ul><ul><li>Instilling supreme attitude and constantly reminding the workforce about 5 S philosophy through training, competition, encouragement by the top management. </li></ul>Toyota Production System
  52. 53. <ul><li>Benefits of JIT </li></ul><ul><li>Reduction of direct and direct labor by eliminating non-value added activities </li></ul><ul><li>Reduction of floor space and warehouse space per unit of output </li></ul><ul><li>Reduction of setup time and schedule delays as the factory becomes a continuous production process. </li></ul><ul><li>Reduction is waste, rejects, and rework by detecting errors at the source. </li></ul><ul><li>Reduction of lead time due to small lot sizes, so that downstream work centers provide feedback on quality problems. </li></ul><ul><li>Better utilization of machines and facilities. </li></ul><ul><li>Better relations with suppliers. </li></ul><ul><li>Better integration of and communication between functions such as marketing, purchasing, design, and production. </li></ul><ul><li>Quality control built into the process. </li></ul>Toyota Production System