SlideShare a Scribd company logo
1 of 19
Download to read offline
Lean Thinking
S. THIRUMALAI
M.Tech.(IE), Dip.SQC & OR, FIIIE.
MANAGEMENT CONSULTANT
Lean is a Health Care
Programme for Organization
Like any Health Care programme for individuals
wherein Techniques are designed to burn out “Fats”
for an individual, Organizations also have “Fats” which
are referred as non-value added activities which are
needed to be eliminated.
Lean Management Definition
A Strategy for achieving Significant Continuous
Improvement in performance through the
Elimination of all wastes of all Resources including
Time.
What really “Lean Management”
want to achieve
“Lean production is lean because it uses less of
everything compared with mass production
half the human effort
half the manufacturing space
half the investment in tools
half the engineering hours to develop a new product in half
the time.
Also it requires keeping far less than half the
needed inventory on site, results in many fewer
defects, and produces a greater and ever-growing
variety of products.”
4
Lean Approach
5
• Identifying Waste
• Process Mapping using Value Stream Mapping
• Identifying Overall Equipment Effectiveness
• Reduction in Set up time (SMED), Quick Changeover (SMED)
• Standardized Work
• Levelled Production
• Pull Scheduling (Kanban)
• Team Development
• Cellular Production
• Error Proofing (Poka Yoke)
• Visual Controls, 5 S
• Total Productive Maintenance
6
Lean Manufacturing Characteristics
7
• Made to order
• Single piece production
• Just in Time supplies
• Pull based scheduling
• Short cycle times
• Highly flexible equipment
• Highly flexible and responsive processes
• Quick changeovers
• Continuous flow (work balancing, cells)
• High first-time right
• Significantly less defects
• Multi-skilled employees
Fundamentals of Lean Manufacturing
8
1. On-Time delivery
2. Improved response
3. Reduced inventory
4. Improved quality
5. Improved workflow
6. Achievement of flexibility
7. Cultural change
8. Better Delegation
9. Better use of plant
WHY COMPANIES INTRODUCE LEAN
10. Better use of skilled labor
11. Job satisfaction
12. Quick Information Flow
13. Less Transactions
14. Less Variation, “More” Predictability
15. Forecasts Become More Accurate
16. Quicker Response To Design Changes
17. Quicker Market Response
18. Problems Are Visible
19. Product Team Organization - Eliminates
Departmental Conflicts
WHY COMPANIES INTRODUCE LEAN
Lead Time Reduction
Productivity Increase
WIP Reduction
Quality Improvement
Space Utilization
0 25 50 75 100
Percentage of Benefits Achieved
4 P’s of LEAN
Problem Solving
· Continual organizational learning through Kaizen
· Go see for yourself to thoroughly understand the system(Genchi Genbutsu)
· Make decisions slowly by consensus thoroughly considering all options; implementing rapidly
People and Partners
· Grow leaders who live the philosophy
· Respect, develop and challenge your people and teams
· Respect challenge and help your suppliers
Process
· Create process ‘flow’ to surface problems
· Use pull system to avoid over production
· Level out work load (Heijunka)
· Stop when there is a quality problem (jidoka)
· Standardize tasks for continuous improvement
· Use visual control so no problems are hidden
· Use only reliable, thoroughly tested technology
4 P’s of LEAN
•Philosophy
• Base management decisions on a long term
philosophy; even at the expense of short term
financial goals
• ‘The need for fast, flexible processes that give
customers what they want, when they want it,
at the highest quality and affordable cost’
LEAN RULES
• Principle 1
Base your management decisions on a long term
philosophy, even at the expense of short-term
financial goals.
• Principle 2
Create continuous process flow to bring problems
to the surface
• Principle 3
Use pull systems to avoid over-production
LEAN RULES
• Principle 4
Level out the workload (heijunka). (Work like the tortoise
and not the hare)
• Principle 5
Build a culture of stopping to fix problems, to get quality
right the first time.
• Principle 6
Standardized tasks are the foundation for continuous
improvement and employee empowerment.
LEAN RULES
Principle 7
• Use visual control so no problems are hidden.
Principle 8
Use only reliable, thoroughly tested technology
that serves your people and processes.
Principle 9
Grow leaders who thoroughly understand the
work, live the philosophy, and teach it to others.
LEAN RULES
Principle 10
Develop exceptional people and teams who follow
your company’s philosophy.
Principle 11
Respect your extended network of partners and
suppliers by challenging them and helping them
improve.
Principle 12
Go and see for yourself
LEAN RULES
Principle 13
Make decisions slowly by consensus,
thoroughly considering all options;
implement decisions rapidly (nemawashi). to
thoroughly understand the situation (genchi
genbutsu).
Principle 14
Become a learning organization through
relentless reflection (hansei) and continuous
improvement (kaizen).
Thank You
info@mybskool.com
http://www.mybskool.com
87545 99124

More Related Content

Viewers also liked

دورة بناء الاهداف ومؤشرات الاداء دكتور مصطفى حامد موسى
دورة بناء الاهداف ومؤشرات الاداء دكتور مصطفى حامد موسىدورة بناء الاهداف ومؤشرات الاداء دكتور مصطفى حامد موسى
دورة بناء الاهداف ومؤشرات الاداء دكتور مصطفى حامد موسىمصطفى حامد
 
Effective Goal Setting - Why You Should Use Goal Setting
Effective Goal Setting - Why You Should Use Goal SettingEffective Goal Setting - Why You Should Use Goal Setting
Effective Goal Setting - Why You Should Use Goal SettingJoan Mullally
 
7 Steps for Achieving Your Goals
7 Steps for Achieving Your Goals7 Steps for Achieving Your Goals
7 Steps for Achieving Your GoalsBianca Woods
 
Goal Setting PowerPoint
Goal Setting PowerPointGoal Setting PowerPoint
Goal Setting PowerPointemurfield
 

Viewers also liked (7)

دورة بناء الاهداف ومؤشرات الاداء دكتور مصطفى حامد موسى
دورة بناء الاهداف ومؤشرات الاداء دكتور مصطفى حامد موسىدورة بناء الاهداف ومؤشرات الاداء دكتور مصطفى حامد موسى
دورة بناء الاهداف ومؤشرات الاداء دكتور مصطفى حامد موسى
 
Effective Goal Setting - Why You Should Use Goal Setting
Effective Goal Setting - Why You Should Use Goal SettingEffective Goal Setting - Why You Should Use Goal Setting
Effective Goal Setting - Why You Should Use Goal Setting
 
Samples SMART Goals
Samples SMART GoalsSamples SMART Goals
Samples SMART Goals
 
7 Steps for Achieving Your Goals
7 Steps for Achieving Your Goals7 Steps for Achieving Your Goals
7 Steps for Achieving Your Goals
 
Goal Setting PowerPoint
Goal Setting PowerPointGoal Setting PowerPoint
Goal Setting PowerPoint
 
Goal setting ppt
Goal setting pptGoal setting ppt
Goal setting ppt
 
GOAL SETTING POWERPOINT
GOAL SETTING POWERPOINTGOAL SETTING POWERPOINT
GOAL SETTING POWERPOINT
 

Recently uploaded

Practical Research 1: Lesson 8 Writing the Thesis Statement.pptx
Practical Research 1: Lesson 8 Writing the Thesis Statement.pptxPractical Research 1: Lesson 8 Writing the Thesis Statement.pptx
Practical Research 1: Lesson 8 Writing the Thesis Statement.pptxKatherine Villaluna
 
Diploma in Nursing Admission Test Question Solution 2023.pdf
Diploma in Nursing Admission Test Question Solution 2023.pdfDiploma in Nursing Admission Test Question Solution 2023.pdf
Diploma in Nursing Admission Test Question Solution 2023.pdfMohonDas
 
Drug Information Services- DIC and Sources.
Drug Information Services- DIC and Sources.Drug Information Services- DIC and Sources.
Drug Information Services- DIC and Sources.raviapr7
 
5 charts on South Africa as a source country for international student recrui...
5 charts on South Africa as a source country for international student recrui...5 charts on South Africa as a source country for international student recrui...
5 charts on South Africa as a source country for international student recrui...CaraSkikne1
 
How to Solve Singleton Error in the Odoo 17
How to Solve Singleton Error in the  Odoo 17How to Solve Singleton Error in the  Odoo 17
How to Solve Singleton Error in the Odoo 17Celine George
 
Quality Assurance_GOOD LABORATORY PRACTICE
Quality Assurance_GOOD LABORATORY PRACTICEQuality Assurance_GOOD LABORATORY PRACTICE
Quality Assurance_GOOD LABORATORY PRACTICESayali Powar
 
In - Vivo and In - Vitro Correlation.pptx
In - Vivo and In - Vitro Correlation.pptxIn - Vivo and In - Vitro Correlation.pptx
In - Vivo and In - Vitro Correlation.pptxAditiChauhan701637
 
How to Add Existing Field in One2Many Tree View in Odoo 17
How to Add Existing Field in One2Many Tree View in Odoo 17How to Add Existing Field in One2Many Tree View in Odoo 17
How to Add Existing Field in One2Many Tree View in Odoo 17Celine George
 
Maximizing Impact_ Nonprofit Website Planning, Budgeting, and Design.pdf
Maximizing Impact_ Nonprofit Website Planning, Budgeting, and Design.pdfMaximizing Impact_ Nonprofit Website Planning, Budgeting, and Design.pdf
Maximizing Impact_ Nonprofit Website Planning, Budgeting, and Design.pdfTechSoup
 
The Stolen Bacillus by Herbert George Wells
The Stolen Bacillus by Herbert George WellsThe Stolen Bacillus by Herbert George Wells
The Stolen Bacillus by Herbert George WellsEugene Lysak
 
How to Add a New Field in Existing Kanban View in Odoo 17
How to Add a New Field in Existing Kanban View in Odoo 17How to Add a New Field in Existing Kanban View in Odoo 17
How to Add a New Field in Existing Kanban View in Odoo 17Celine George
 
Human-AI Co-Creation of Worked Examples for Programming Classes
Human-AI Co-Creation of Worked Examples for Programming ClassesHuman-AI Co-Creation of Worked Examples for Programming Classes
Human-AI Co-Creation of Worked Examples for Programming ClassesMohammad Hassany
 
2024.03.23 What do successful readers do - Sandy Millin for PARK.pptx
2024.03.23 What do successful readers do - Sandy Millin for PARK.pptx2024.03.23 What do successful readers do - Sandy Millin for PARK.pptx
2024.03.23 What do successful readers do - Sandy Millin for PARK.pptxSandy Millin
 
Benefits & Challenges of Inclusive Education
Benefits & Challenges of Inclusive EducationBenefits & Challenges of Inclusive Education
Benefits & Challenges of Inclusive EducationMJDuyan
 
The basics of sentences session 10pptx.pptx
The basics of sentences session 10pptx.pptxThe basics of sentences session 10pptx.pptx
The basics of sentences session 10pptx.pptxheathfieldcps1
 
CHUYÊN ĐỀ DẠY THÊM TIẾNG ANH LỚP 11 - GLOBAL SUCCESS - NĂM HỌC 2023-2024 - HK...
CHUYÊN ĐỀ DẠY THÊM TIẾNG ANH LỚP 11 - GLOBAL SUCCESS - NĂM HỌC 2023-2024 - HK...CHUYÊN ĐỀ DẠY THÊM TIẾNG ANH LỚP 11 - GLOBAL SUCCESS - NĂM HỌC 2023-2024 - HK...
CHUYÊN ĐỀ DẠY THÊM TIẾNG ANH LỚP 11 - GLOBAL SUCCESS - NĂM HỌC 2023-2024 - HK...Nguyen Thanh Tu Collection
 
What is the Future of QuickBooks DeskTop?
What is the Future of QuickBooks DeskTop?What is the Future of QuickBooks DeskTop?
What is the Future of QuickBooks DeskTop?TechSoup
 
How to Show Error_Warning Messages in Odoo 17
How to Show Error_Warning Messages in Odoo 17How to Show Error_Warning Messages in Odoo 17
How to Show Error_Warning Messages in Odoo 17Celine George
 

Recently uploaded (20)

Practical Research 1: Lesson 8 Writing the Thesis Statement.pptx
Practical Research 1: Lesson 8 Writing the Thesis Statement.pptxPractical Research 1: Lesson 8 Writing the Thesis Statement.pptx
Practical Research 1: Lesson 8 Writing the Thesis Statement.pptx
 
Personal Resilience in Project Management 2 - TV Edit 1a.pdf
Personal Resilience in Project Management 2 - TV Edit 1a.pdfPersonal Resilience in Project Management 2 - TV Edit 1a.pdf
Personal Resilience in Project Management 2 - TV Edit 1a.pdf
 
Diploma in Nursing Admission Test Question Solution 2023.pdf
Diploma in Nursing Admission Test Question Solution 2023.pdfDiploma in Nursing Admission Test Question Solution 2023.pdf
Diploma in Nursing Admission Test Question Solution 2023.pdf
 
Drug Information Services- DIC and Sources.
Drug Information Services- DIC and Sources.Drug Information Services- DIC and Sources.
Drug Information Services- DIC and Sources.
 
5 charts on South Africa as a source country for international student recrui...
5 charts on South Africa as a source country for international student recrui...5 charts on South Africa as a source country for international student recrui...
5 charts on South Africa as a source country for international student recrui...
 
How to Solve Singleton Error in the Odoo 17
How to Solve Singleton Error in the  Odoo 17How to Solve Singleton Error in the  Odoo 17
How to Solve Singleton Error in the Odoo 17
 
Quality Assurance_GOOD LABORATORY PRACTICE
Quality Assurance_GOOD LABORATORY PRACTICEQuality Assurance_GOOD LABORATORY PRACTICE
Quality Assurance_GOOD LABORATORY PRACTICE
 
In - Vivo and In - Vitro Correlation.pptx
In - Vivo and In - Vitro Correlation.pptxIn - Vivo and In - Vitro Correlation.pptx
In - Vivo and In - Vitro Correlation.pptx
 
How to Add Existing Field in One2Many Tree View in Odoo 17
How to Add Existing Field in One2Many Tree View in Odoo 17How to Add Existing Field in One2Many Tree View in Odoo 17
How to Add Existing Field in One2Many Tree View in Odoo 17
 
Maximizing Impact_ Nonprofit Website Planning, Budgeting, and Design.pdf
Maximizing Impact_ Nonprofit Website Planning, Budgeting, and Design.pdfMaximizing Impact_ Nonprofit Website Planning, Budgeting, and Design.pdf
Maximizing Impact_ Nonprofit Website Planning, Budgeting, and Design.pdf
 
The Stolen Bacillus by Herbert George Wells
The Stolen Bacillus by Herbert George WellsThe Stolen Bacillus by Herbert George Wells
The Stolen Bacillus by Herbert George Wells
 
How to Add a New Field in Existing Kanban View in Odoo 17
How to Add a New Field in Existing Kanban View in Odoo 17How to Add a New Field in Existing Kanban View in Odoo 17
How to Add a New Field in Existing Kanban View in Odoo 17
 
Human-AI Co-Creation of Worked Examples for Programming Classes
Human-AI Co-Creation of Worked Examples for Programming ClassesHuman-AI Co-Creation of Worked Examples for Programming Classes
Human-AI Co-Creation of Worked Examples for Programming Classes
 
Finals of Kant get Marx 2.0 : a general politics quiz
Finals of Kant get Marx 2.0 : a general politics quizFinals of Kant get Marx 2.0 : a general politics quiz
Finals of Kant get Marx 2.0 : a general politics quiz
 
2024.03.23 What do successful readers do - Sandy Millin for PARK.pptx
2024.03.23 What do successful readers do - Sandy Millin for PARK.pptx2024.03.23 What do successful readers do - Sandy Millin for PARK.pptx
2024.03.23 What do successful readers do - Sandy Millin for PARK.pptx
 
Benefits & Challenges of Inclusive Education
Benefits & Challenges of Inclusive EducationBenefits & Challenges of Inclusive Education
Benefits & Challenges of Inclusive Education
 
The basics of sentences session 10pptx.pptx
The basics of sentences session 10pptx.pptxThe basics of sentences session 10pptx.pptx
The basics of sentences session 10pptx.pptx
 
CHUYÊN ĐỀ DẠY THÊM TIẾNG ANH LỚP 11 - GLOBAL SUCCESS - NĂM HỌC 2023-2024 - HK...
CHUYÊN ĐỀ DẠY THÊM TIẾNG ANH LỚP 11 - GLOBAL SUCCESS - NĂM HỌC 2023-2024 - HK...CHUYÊN ĐỀ DẠY THÊM TIẾNG ANH LỚP 11 - GLOBAL SUCCESS - NĂM HỌC 2023-2024 - HK...
CHUYÊN ĐỀ DẠY THÊM TIẾNG ANH LỚP 11 - GLOBAL SUCCESS - NĂM HỌC 2023-2024 - HK...
 
What is the Future of QuickBooks DeskTop?
What is the Future of QuickBooks DeskTop?What is the Future of QuickBooks DeskTop?
What is the Future of QuickBooks DeskTop?
 
How to Show Error_Warning Messages in Odoo 17
How to Show Error_Warning Messages in Odoo 17How to Show Error_Warning Messages in Odoo 17
How to Show Error_Warning Messages in Odoo 17
 

Lean thinking - Management Topic from myBskool | Online Mini MBA (Free)

  • 1. Lean Thinking S. THIRUMALAI M.Tech.(IE), Dip.SQC & OR, FIIIE. MANAGEMENT CONSULTANT
  • 2. Lean is a Health Care Programme for Organization Like any Health Care programme for individuals wherein Techniques are designed to burn out “Fats” for an individual, Organizations also have “Fats” which are referred as non-value added activities which are needed to be eliminated.
  • 3. Lean Management Definition A Strategy for achieving Significant Continuous Improvement in performance through the Elimination of all wastes of all Resources including Time.
  • 4. What really “Lean Management” want to achieve “Lean production is lean because it uses less of everything compared with mass production half the human effort half the manufacturing space half the investment in tools half the engineering hours to develop a new product in half the time. Also it requires keeping far less than half the needed inventory on site, results in many fewer defects, and produces a greater and ever-growing variety of products.” 4
  • 5. Lean Approach 5 • Identifying Waste • Process Mapping using Value Stream Mapping • Identifying Overall Equipment Effectiveness • Reduction in Set up time (SMED), Quick Changeover (SMED) • Standardized Work • Levelled Production • Pull Scheduling (Kanban) • Team Development • Cellular Production • Error Proofing (Poka Yoke) • Visual Controls, 5 S • Total Productive Maintenance
  • 6. 6
  • 7. Lean Manufacturing Characteristics 7 • Made to order • Single piece production • Just in Time supplies • Pull based scheduling • Short cycle times • Highly flexible equipment • Highly flexible and responsive processes • Quick changeovers • Continuous flow (work balancing, cells) • High first-time right • Significantly less defects • Multi-skilled employees
  • 8. Fundamentals of Lean Manufacturing 8
  • 9. 1. On-Time delivery 2. Improved response 3. Reduced inventory 4. Improved quality 5. Improved workflow 6. Achievement of flexibility 7. Cultural change 8. Better Delegation 9. Better use of plant WHY COMPANIES INTRODUCE LEAN
  • 10. 10. Better use of skilled labor 11. Job satisfaction 12. Quick Information Flow 13. Less Transactions 14. Less Variation, “More” Predictability 15. Forecasts Become More Accurate 16. Quicker Response To Design Changes 17. Quicker Market Response 18. Problems Are Visible 19. Product Team Organization - Eliminates Departmental Conflicts WHY COMPANIES INTRODUCE LEAN
  • 11. Lead Time Reduction Productivity Increase WIP Reduction Quality Improvement Space Utilization 0 25 50 75 100 Percentage of Benefits Achieved
  • 12. 4 P’s of LEAN Problem Solving · Continual organizational learning through Kaizen · Go see for yourself to thoroughly understand the system(Genchi Genbutsu) · Make decisions slowly by consensus thoroughly considering all options; implementing rapidly People and Partners · Grow leaders who live the philosophy · Respect, develop and challenge your people and teams · Respect challenge and help your suppliers Process · Create process ‘flow’ to surface problems · Use pull system to avoid over production · Level out work load (Heijunka) · Stop when there is a quality problem (jidoka) · Standardize tasks for continuous improvement · Use visual control so no problems are hidden · Use only reliable, thoroughly tested technology
  • 13. 4 P’s of LEAN •Philosophy • Base management decisions on a long term philosophy; even at the expense of short term financial goals • ‘The need for fast, flexible processes that give customers what they want, when they want it, at the highest quality and affordable cost’
  • 14. LEAN RULES • Principle 1 Base your management decisions on a long term philosophy, even at the expense of short-term financial goals. • Principle 2 Create continuous process flow to bring problems to the surface • Principle 3 Use pull systems to avoid over-production
  • 15. LEAN RULES • Principle 4 Level out the workload (heijunka). (Work like the tortoise and not the hare) • Principle 5 Build a culture of stopping to fix problems, to get quality right the first time. • Principle 6 Standardized tasks are the foundation for continuous improvement and employee empowerment.
  • 16. LEAN RULES Principle 7 • Use visual control so no problems are hidden. Principle 8 Use only reliable, thoroughly tested technology that serves your people and processes. Principle 9 Grow leaders who thoroughly understand the work, live the philosophy, and teach it to others.
  • 17. LEAN RULES Principle 10 Develop exceptional people and teams who follow your company’s philosophy. Principle 11 Respect your extended network of partners and suppliers by challenging them and helping them improve. Principle 12 Go and see for yourself
  • 18. LEAN RULES Principle 13 Make decisions slowly by consensus, thoroughly considering all options; implement decisions rapidly (nemawashi). to thoroughly understand the situation (genchi genbutsu). Principle 14 Become a learning organization through relentless reflection (hansei) and continuous improvement (kaizen).