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lean manufacturing

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Kaizen Institute India shared the latest development & trends related to Operational Excellence at this conclave - Kaizen incorporates a variety of techniques and principles into the overall culture and philosophy of improvement–improvement as a way of life, rather than the application of isolated techniques.

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lean manufacturing

  1. 1. 1KAIZEN and GEMBAKAIZENare the trademarks of KAIZEN Institute1LEAN MANUFACTURING COMPETITIVENESSPROGRAMME
  2. 2. 2KAIZEN and GEMBAKAIZENare the trademarks of KAIZEN InstituteWHAT IS LEAN MANUFACTURING ?• It is the production of goods, using less of everything, i.e;- less human effort- less manufacturing space- less investment in tools- less engineering time etc.• It is a business initiative to reduce “waste” in manufacturedproducts.• Lean is one of the latest management tools in costreduction .
  3. 3. 3KAIZEN and GEMBAKAIZENare the trademarks of KAIZEN InstituteHOW DOES LEAN MANUFACTURING WORK ?It reduces cost by:• Improving labour use.• Decreasing inventories.• Reducing manufacturing order to shipment cycle time.• Increasing capacities, without substantial capital inputs
  4. 4. 4KAIZEN and GEMBAKAIZENare the trademarks of KAIZEN InstituteWHAT DOES LEAN MANUFACTURING DO ?• Helps firms produce more with the same resourcesby eliminating the non-value addedactivities.• Applies simple techniques to identify / eliminate thewastage and streamline systems.• Focuses on improving the entire process flow.• Emphasizes worker empowerment throughout[“Decent Work”]
  5. 5. 5KAIZEN and GEMBAKAIZENare the trademarks of KAIZEN InstituteTECHNIQUES OF LEAN MANUFACTURING• 5S System• Visual Control• Standard Operation Procedures (SOPs)• Just in Time (JIT)• KANBAN System• Cellular Layout• Value Stream Mapping• POKA YOKE or Mistake Proofing• SMED (Single Minutes Exchange of Dies or Quick Changeover)• TPM (Total Productive Maintenance)• KAIZEN BLITZ-Rapid Improvement Process
  6. 6. 6KAIZEN and GEMBAKAIZENare the trademarks of KAIZEN InstituteDELIVERABLES• Unit level Deliverables:- Reduction of Costs.- Reduction of Cycle Time.- Lowering of Defects / Rework Cost.- Reduction of System related Wastes.
  7. 7. 7KAIZEN and GEMBAKAIZENare the trademarks of KAIZEN InstituteDELIVERABLES (Contd…)• Expected “externals”:- Skill up-gradation of Labour.- Improvement of Techniques.- Increase in Labour Productivity.- Lowering in-put cost of other industries.- Introducing of new production equipments / methods.- Betterment of work culture in society.- Development of a large pool of Lean Consultants.- Trigger competitiveness as a chain reaction.- Build a strong structure in private sector to sustaincontinuity of market driven requirements.
  8. 8. 8KAIZEN and GEMBAKAIZENare the trademarks of KAIZEN InstituteRETURN ON INVESTMENT [ROI]• Industries’ norm for wastage =- Developed countries 10 - 20 % of turnover.- Developing countries 20 – 30 % of turnover.
  9. 9. 9KAIZEN and GEMBAKAIZENare the trademarks of KAIZEN InstituteKAIZEN Management System®
  10. 10. 10KAIZEN and GEMBAKAIZENare the trademarks of KAIZEN Institute®KAIZEN®andGEMBAKAIZEN®areregistered trade marksofKAIZEN INSTITUTE Ltd.Thank you!

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