3. I. Definition
Lean manufacturing or lean production is a method for
waste minimization within a manufacturing system
without sacrificing productivity. Lean manufacturing is a
way to eliminate everything that does not add value
(waste) in the customer’s eyes, and improve efficiency in a
manufacturing environment.
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4. II. Objective
Eliminate non value added activates
Minimize the work in process inventory
Meet customer demand on time
Create flexibility of style change over
Creating multi-skilled operator responding quickly
for style change over
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5. III. Principles Lean Manufacturing
The five-step thought process for
guiding the implementation of lean techniques:
1. Identify value
2. Map the value stream
3. Create flow
4. Establish Pull
5. Seek perfection.
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6. III. Principles Lean Manufacturing (Cont.)
Identify value
Value is always defined by the customer’s needs for a
specific product.
Specify value from the standpoint of the end customer by
product family
For example, what is the timeline for manufacturing and
delivery? What is the price point? What are other
important requirements or expectations that must be met?
This information is vital for defining value
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7. III. Principles Lean Manufacturing (Cont.)
Map the value stream
This involves every step of the process starting from the
supplier and ending with the customer. Every step must
bring the product closer to the completion and add value to
it.
Thus, we have to identify all the steps in the value stream
for each product family, eliminating whenever possible
those steps that do not create value
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8. III. Principles Lean Manufacturing (Cont.)
Create flow
After the waste has been removed from the value stream,
the next step is to be sure the remaining steps flow
smoothly with no interruptions, delays, or bottlenecks.
Make the value creating steps occur in tight sequence so
the product will flow smoothly toward the customer.
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9. III. Principles Lean Manufacturing (Cont.)
Establish Pull
Producing what the customer needs
And avoid over productivity that increase the most
of ever wastes in the production process.
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10. III. Principles Lean Manufacturing (Cont.)
Seek perfection.
As value is specified, value stream are specified, waste
step are removed, and flow and pull are introduced, begin
the process again and continue it until a state of perfection
is reached in which perfect value is created with no waste.
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11. IV. Type of wastes
There are 7 majors type of non-value-adding wastes in
business or miniaturing process:
1. Waste of over-production
2. Waste of unnecessary Motion
3. Waste of inventory
4. Waste of defect
5. Waste of waiting (Queues)
6. Waste of transportation
7. Waste of over processing
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12. 7 types of wastes
Waste of over-production: Is the worst of the 7 wastes of
lean manufacturing producing more than the customer order
or producing early (over the capacity of the selling
department is a waste of money in enormous rates).
Inventory of any kind is usually waste
Waste of unnecessary Motion: Movement of equipment or
people.
Waste of inventory: Unnecessary raw material, work in
process(WIP), finished goods, and excess operating
suppliers
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13. 7 types of wastes (Cont.)
Waste of defect: Returns, warranty claims, rework and scrap
Waste of waiting (Queues): Idle time, storage, and waiting
are wastes
Waste of transportation: Moving material between plants,
between work centers and handing more than once is waste
Waste of over processing: Work performance on product
that adds no value
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14. V. Lean Manufacturing Methodologies
There are many methods of lean manufacturing such as:
➢ Total 5S
➢ Standardize Work
➢ Poka yoke
➢ Just in time
➢ Continuous improvement (Kaizen)
➢ Takt Time Pull Flow
➢ Material Management, Work in process, Lean Six Sigma,
Jidoka, etc.
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15. V. Lean Manufacturing Methodologies (Cont.)
➢Total 5S:
5S is a tools set of 5S, 3 right’s and visual management
SORT: Remove unnecessary items from the work area. Attach
removal tags to infrequently used items.
SET IN ORDER: Customize the work area to improve efficiency, and
Keep important materials nearby, implement visual organization to
streamline workflow and improve efficiency.
SHINE: Clean the work area, equipment and tool. Find and eliminate
source of contamination.
STANDARDIZE: Create the standardize and consistent 5S work
flow. Assign task and create schedule so that everyone knows their
responsibility.
SUSTAIN: Ensure that 5S is a long-term. Companywide goal,
analysis result, hold team meeting and train workers on the importins
of 5S.
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16. Advantage of applying Total 5S:
➢ Increase the level of manufacturing
➢ Safe production environment
➢ Increase the level of quality
➢ Shorten Preparatory Working time
➢ Increase Maintenance level
➢ Decrease lot of losses dramatically can cut off production
cost through 5S which reduce visible losses inside
manufacturing line
16 V. Lean Manufacturing Methodologies (Cont.)
17. ➢Standardized work:
In a lean manufacturing environment, standardized work is a
key element to success. By repeating a set method, the
process is more organized and improvement opportunities
become more apparent.
The main elements of standardized work are:
▪ takt time
▪ work sequence
▪ and standard in-process stock.
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Figure: Element of Standardize work
V. Lean Manufacturing Methodologies (Cont.)
18. ➢Just in Time (JIT)
• Just in time (JIT) production means producing the right item,
at the right time, and right quantity. JIT is a system whether
company starts manufacturing or purchasing once the
customer orders the good effectively making zero
inventories.
• In other words, in JIT environment materials are purchased
and produced as and when it is needed.
• JIT consists of many other lean tools such as: Kanban,
production leveling, SMED or quick machine changeovers,
visual management, and having a stable process which is a
benefit of many different lean tools such as 5s, TPM, and
standardized.
18 V. Lean Manufacturing Methodologies (Cont.)
19. ➢Lean Six sigma:
Six Sigma (6σ) quality is a problem-solving
methodology. it represents the mathematical
calculation, 99.9996% perfection
Six sigma is about reducing variation while
aligning the mean
Six sigma is about doing right thing the first
time
Six sigma is about producing high quality with
less money
Six sigma is not about working hard but
working smarter.
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20. VI. Conclusion
In Lean Manufacturing, there are many tools which use to
Improve quality, Eliminate waste, Reduce time, Reduce
total costs, and develops an easier way for the
management to coordinate the factory production.
One more thing, the decease number of operators,
operation and time, which in turn increase the profit for
the firm.
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