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Lean manufacturing concepts and tools and quality management1


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Lean manufacturing concepts and tools and quality management1

  1. 1. Lean Manufacturing Concepts and Tools and Quality Management By Hristina Koycheva
  2. 2. What is Lean? <ul><li>Lean is an Operational Excellence Strategy that enable you to change for the better- in fact the Japanese often use “Kaizen” which use by lean practitioners to describe incremental improvements ; </li></ul>
  3. 3. What is Lean? <ul><li>Persistent process in elimination of waste – MUDA – describes any activity that’s done, but add no real value to the product or service. </li></ul>
  4. 4. What is Lean? <ul><li>Respect for people </li></ul><ul><li>High Quality and Stable Processes </li></ul>
  5. 5. Where? <ul><li>At all level there is a strong desire to be better; </li></ul><ul><li>A culture of lean is visibly prioritised and practice from the top to the bottom of the workforce; </li></ul><ul><li>The key is understanding the customer and delivering his requirements; </li></ul>
  6. 6. How? <ul><li>Improves business performance using simple practical tools and techniques to enhance quality, cost, delivery and people contribution; </li></ul><ul><li>Exposes the wastes in the system; </li></ul><ul><li>People need to change their long standing work practices and ideas; </li></ul><ul><li>Senior management need to drive lean principles forward with total commitment to its success; </li></ul><ul><li>Not a “bolt on” technique, more a way of life leading to a total change in culture . </li></ul>
  7. 7. Short History <ul><li>1913: Henry Ford (Start of mass manufacturing with the moving line) </li></ul><ul><li>1938 JIT Born </li></ul>
  8. 8. Short History <ul><li>1950: Eiji Toyoda brings the ideas of continuous moving line in Japan </li></ul>
  9. 9. Short History <ul><li>1960: Toyota production System, main principles of lean manufacturing </li></ul><ul><li>1991: Lean Management </li></ul>
  10. 10. Main Principals <ul><li>Identify the customer </li></ul><ul><li>Map the flow </li></ul><ul><li>Make a product or service flow </li></ul><ul><li>Create polls based on customer demands </li></ul><ul><li>Continually find ways to improve </li></ul>
  11. 11. Lean Tools <ul><li>Assessment and planning- fundamentals and understanding where we are today and creating and design for tomorrow. </li></ul><ul><li>Plan, Do, Check, Act </li></ul>
  12. 12. Lean Tools <ul><li>5 “S” </li></ul><ul><li>Visual control </li></ul><ul><li>Standardize work </li></ul><ul><li>Total productive maintenance </li></ul>
  13. 13. Select the key <ul><li>Reduce cost of production </li></ul><ul><li>Increase customer satisfaction </li></ul><ul><li>Improve quality </li></ul>Select the key Map Process Eliminate Waste Make Process Flow Establish Customer Poll
  14. 14. What Is Waste? <ul><li>Waste of overproduction (largest waste) </li></ul><ul><li>Waste of time on hand (waiting) </li></ul><ul><li>Waste of transportation </li></ul><ul><li>Waste of processing itself </li></ul><ul><li>Waste of stock at hand </li></ul><ul><li>Waste of movement </li></ul><ul><li>Waste of making defective products </li></ul>
  15. 15. Lean Thinking Key Principals of Lean Thinking <ul><li>Value - what customers are willing to pay for; </li></ul><ul><li>Value Stream – the steps are delivered value; </li></ul><ul><li>Flow – organizing Value Stream to be continuous; </li></ul><ul><li>Polls – responding to downstream customer demand; </li></ul><ul><li>Perfection – relentless continuous improvement (culture); </li></ul>Lean Thinking, Womack and Jones,1996
  16. 16. Conclusion <ul><li>Lean is: </li></ul><ul><li>“ A systematic approach to identifying and eliminating waste (non-value added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection .” </li></ul>
  17. 17. Production System <ul><li>Two pillars: </li></ul><ul><li>Jidoka </li></ul><ul><li>Just-in-time </li></ul>
  18. 18. What is Jidoka? <ul><li>“ Jidoka” means autonomous . The responsibility of each associate to deliver Quality to the customers. </li></ul><ul><li>- Intense Motivation Training; </li></ul><ul><li>- Explained Information; </li></ul>
  19. 19. Just-in-time <ul><li>Aims of zero inventory; </li></ul><ul><li>Parts are not kept in warehouse; </li></ul><ul><li>Parts arrive when needed; </li></ul>
  20. 20. Quality system <ul><li>Quality means compliance with specifications- no less, no more; </li></ul><ul><li>No need for inspections! </li></ul>
  21. 21. Quality Assurance <ul><li>When we focused on this we will consistently deliver what the customer expects; </li></ul><ul><li>Trust raises everyone’s commitment </li></ul>
  22. 23. Thank you!