This document discusses lean manufacturing practices such as cellular layout, point-of-use storage, linked cell manufacturing, and the principles of lean systems including value, value stream, flow, pull, and continuous improvement. It also discusses how simulation software like WorkPro, ProModel, and Arena can be used for layout optimization, problem solving, and factory simulation to support lean practices. Ergonomics and its importance in lean is discussed. The goals of lean manufacturing are listed as less labor/floor space, fewer design/defect hours, less stock, faster delivery, improved ergonomics, and maximum flexibility.
Similar to Virtual Lean Manufacturing Practices for Lean Manufacturing, Line Balancing, Kaizen, Flow Path Analysis, SMED, Ergonomics, Scheduling Analysis
Similar to Virtual Lean Manufacturing Practices for Lean Manufacturing, Line Balancing, Kaizen, Flow Path Analysis, SMED, Ergonomics, Scheduling Analysis (20)
13. Lean Manufacturing?
• Large batches
• Excessive inventory
• Long lead times
• Excessive work in progress
• Disorganized shop floor with no space
• High costs
• Low percent of on-time deliveries
• Difficulty in meeting customer needs
• Not competitive—having selling price too high
21. The Principles of a Lean Manufacturing System
• Value—Customer’s willingness to pay for your product.
• Value Stream—Add-ons to a product or process.
• Flow—The movement of your product through a single piece flow or
work cells rather than production lines.
• Pull—Having the right amount of materials to manufacture the
product, and at the same time, having a small or no inventory.
• Continuous Improvement—Getting rid of waste on a constant basis.
31. Hence, Lean Manufacturing
Aims at,
• Less labor and floor space.
• Fewer design hours for product development.
• Less stock on hand.
• Fewer defects.
• Quality.
• Faster delivery.
• Improved ergonomics.
• Maximum flexibility in product types and styles produced.
32. Lean and Ergonomics
Safety and ergonomics should be one of the core values of the
lean process
• Identify work process to improve
• Stakeholder involvement
• Ergonomics training
• Ergonomic design
• Quantifying the impact of ergonomic changes
• Creating shared belief for the benefit of ergonomics
33. Waste
Waste of motion that does not add value
• Can lead to muscle fatigue
Waste of manual effort
• Can lead to muscle fatigue
Waste of movements to transport material
• Can lead to muscle fatigue and strains
Waste of time to rework, repair, or scrap
• May be related to fatigue, strains or sprains
• Focus on self and not on job
35. Group Technology / Cellular Manufacturing
• Improved material flow
• Reduced queuing time
• Reduced inventory
• Improved use of space
• Improved team work
• Reduced waste
• Increased flexibility