LEAN MANUFACTURING

1. HELLO!
We are group 5
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Presented by
Muktadir Rahman
Anej Chakma
Ahnaf Istiaque Adit
M.A. Mohaimin
Shafayet Hossain Sifat

2. LEAN
MANUFACTURING

3. What is LeanManufacturing?
“Lean Manufacturing, also called Lean
Production, is a set of tools and
methodologies that aims for the
continuous elimination of all waste in
the production process. The main
benefits of this are lower production
costs, increased output and shorter
production lead times”
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“A systematic approach to identifying
and eliminating waste and NVA (non-
value added activity) through
continuous improvement and flowing
the product at the pull of the customer
in pursuit of perfection”.

4. OBJECTIVES
– Defects and Wastage
• Reduce defects and unnecessary physical wastage
• Unnecessary features
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– Reduce manufacturing lead times
– Labor Productivity
• Reducing the idle time of workers
• Utilization of equipment and space
– Flexibility
– Output

5. 7 Types of Waste
1. Waiting Waste.
2. Defects and Rejects Waste
3. Inventory Waste
4. Overproduction Waste
5. Over-Processing Waste
6. Motion Waste
7. Transportation Waste
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Methods of Lean Manufacturing
1) Select the target or product.
2) Gemba walk, for the collecting data
3) Analyzation of data and take decision
4) Improving the problem and decide the lean tools which
give tools maximum result

7. Key Principles of Lean Manufacturing
▫ Recognition of waste
▫ Standard Processes
▫ Map the Flow
▫ Make A product or Service Flow
▫ Quality at the Source
▫ Continuous Improvement
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8. BENEFITS OF LEAN
▫ Reduction in production cost 3.44% & 14.28%
▫ Productivity improvement 10% to 50%
▫ Reduction in production lead time 8% to 25%
▫ Garment quality improvement 10% to 35%
▫ Reduction in production cycle time 12.5% to 33%
▫ Annual saving Up to 44%
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KEY PARAMETERS
RESULTS FROM LEAN
IMPLEMENTATION

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Challenges in Lean Implementation and Sustainability
▫ Fear to change the legacy system with the new successful
trends and methodologies
▫ Not utilizing the opportunities and advantages of the new
policies
▫ Market destabilization will lead to force the change, which
will be in a non-standard format.

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Review of Lean Implementation Techniques
1. 5s Model.
2. Total Productive maintenance (TPM).
3. Cellular manufacturing
4. Just in time (JIT)
5. Double card kanban system
6. Single Card Kanban System
7. Scheduling
8. Value stream mapping

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Lean Manufacturing techniques are
applying
Color industry VSM 5s Decrease lead time. Reduced value
added.
Plastic product
of health care.
5-why Ishikawa chart Reduced lead time. Inventory control.
Bearing VSM Reduced work In process inventory and lead time.
Fishing net VSM Increase service level, Reduced work
in process.
Truck body VSM Tree diagram Reduced Cycle time.
Crank shaft VSM KAIZEN Eliminate inventory between two
machines. Quick response to customer. Single piece Flow established.
Auto mobile
industry
Weighted average
method
5s, OEE, 8 step Problem solving method, pareto analysis, Elimination of
waste, this five tools are very effective
in lean production.
Auto mobile Parts industry 5s Kaizen Reduced break down time.
Performance efficiency improves.

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Thank you