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Lean manufacturing concepts

Satyendra Sinha
Satyendra Sinha
Satyendra SinhaManager at Amtech Electronics India Ltd , Gandhinagar , Gujrat

All lean tools

Lean manufacturing concepts

1 of 45
1/16/2020 Lean Manufacturing Concepts
https://leanabc.blogspot.com 1/45
Lean Manufacturing Concepts and Lean manufacturing tools i.e. 5S,3M ,JIT,Kaizen ,Kanban ,OEE,PDCA
,Poka-Yoke , SMED,VSM etc .
Lean Manufacturing ConceptsLean Manufacturing Concepts
M o n d a y , 1 3 J a n u a r y 2 0 2 0
Lean Principle for Cost Reduction
Traditional thinking dictates that you set your selling price by
calculating your cost and adding on a margin for profit
Satyendra Sinha
Bhopal, MADHYA
PRADESH, India
I am Master in Science
& Technology with MBA
in Operations having over 25 years
experience in Management in
Manufacturing Industries.
View my complete profile
About Me
Report Abuse
Enter your email address:
Subscribe
Email Subscription
More satyendrasinha68@gmail.com New Post Design Sign Out
1/16/2020 Lean Manufacturing Concepts
https://leanabc.blogspot.com 2/45
In today’s competitive market the customer sets the price
and you don’t have the luxury of adding aprofit margin
The only way to remain profitable and grow your business
is to eliminate waste from your value stream, thereby
reducing costs—cost reduction principle
Eliminating waste is important because customers not only set the price, but
they also demand price reductions
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Lean Manufacturing Concepts
and Lean manufacturing tools
i.e. 5S,3M ,JIT,Kaizen
,Kanban ,OEE,PDCA ,Poka-
Yoke , SMED,VSM etc .
LeanLean
ManufacturinManufacturin
g Conceptsg Concepts
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1/16/2020 Lean Manufacturing Concepts
https://leanabc.blogspot.com 3/45
at January 13, 2020 No comments: Links to this post
W e d n e s d a y , 8 J a n u a r y 2 0 2 0
PDCA-Deming PDCA cycle
Video Of Day
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1/16/2020 Lean Manufacturing Concepts
https://leanabc.blogspot.com 4/45
PDCA, Plan-Do-Check-Act cycle is an essential part of the lean manufacturing
for continuous improvement of people and processes.
Plan – Identify the problem, collect relevant data, and understand the problem's root
cause, develop hypotheses about what the issues may be, and decide which one to test.
First, proposed by Walter Shewhart and later developed by William
Deming, PDCA cycle is a simple four-stage method that enables teams to
avoid recurring mistakes and improve processes.
1/16/2020 Lean Manufacturing Concepts
https://leanabc.blogspot.com 5/45
Do – Develop and implement a solution; decide upon a measurement to gauge its
effectiveness, test the potential solution, and measure the results.
Check – Confirm the results through before-and-after data comparison. Study the result,
measure effectiveness, and decide whether the hypothesis is supported or not.
1/16/2020 Lean Manufacturing Concepts
https://leanabc.blogspot.com 6/45
at January 08, 2020 No comments: Links to this post
Act – Document the results, inform others about process changes, and make
recommendations for the future PDCA cycles. If the solution was successful, implement it. If
not, tackle the next problem and repeat the PDCA cycle again..
SMED (Single-Minute Exchange of Dies)
WHAT IS SMED?
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Lean manufacturing concepts

  • 1. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 1/45 Lean Manufacturing Concepts and Lean manufacturing tools i.e. 5S,3M ,JIT,Kaizen ,Kanban ,OEE,PDCA ,Poka-Yoke , SMED,VSM etc . Lean Manufacturing ConceptsLean Manufacturing Concepts M o n d a y , 1 3 J a n u a r y 2 0 2 0 Lean Principle for Cost Reduction Traditional thinking dictates that you set your selling price by calculating your cost and adding on a margin for profit Satyendra Sinha Bhopal, MADHYA PRADESH, India I am Master in Science & Technology with MBA in Operations having over 25 years experience in Management in Manufacturing Industries. View my complete profile About Me Report Abuse Enter your email address: Subscribe Email Subscription More satyendrasinha68@gmail.com New Post Design Sign Out
  • 2. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 2/45 In today’s competitive market the customer sets the price and you don’t have the luxury of adding aprofit margin The only way to remain profitable and grow your business is to eliminate waste from your value stream, thereby reducing costs—cost reduction principle Eliminating waste is important because customers not only set the price, but they also demand price reductions Delivered by FeedBurner Name Email * Message * Send Contact Form Lean Manufacturing Concepts and Lean manufacturing tools i.e. 5S,3M ,JIT,Kaizen ,Kanban ,OEE,PDCA ,Poka- Yoke , SMED,VSM etc . LeanLean ManufacturinManufacturin g Conceptsg Concepts https://www.facebook.com/satyendra.sinha.33 Find Us On Facebook
  • 3. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 3/45 at January 13, 2020 No comments: Links to this post W e d n e s d a y , 8 J a n u a r y 2 0 2 0 PDCA-Deming PDCA cycle Video Of Day Follow by Email Email Submit Search Search This Blog Home About me Contact us Privacy Policy
  • 4. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 4/45 PDCA, Plan-Do-Check-Act cycle is an essential part of the lean manufacturing for continuous improvement of people and processes. Plan – Identify the problem, collect relevant data, and understand the problem's root cause, develop hypotheses about what the issues may be, and decide which one to test. First, proposed by Walter Shewhart and later developed by William Deming, PDCA cycle is a simple four-stage method that enables teams to avoid recurring mistakes and improve processes.
  • 5. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 5/45 Do – Develop and implement a solution; decide upon a measurement to gauge its effectiveness, test the potential solution, and measure the results. Check – Confirm the results through before-and-after data comparison. Study the result, measure effectiveness, and decide whether the hypothesis is supported or not.
  • 6. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 6/45 at January 08, 2020 No comments: Links to this post Act – Document the results, inform others about process changes, and make recommendations for the future PDCA cycles. If the solution was successful, implement it. If not, tackle the next problem and repeat the PDCA cycle again.. SMED (Single-Minute Exchange of Dies) WHAT IS SMED?
  • 7. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 7/45 BASICS OF SMED SMED was developed by Shigeo Shingo, a Japanese industrial engineer who was extraordinarily successful in helping companies dramatically reduce their changeover times. His pioneering work led to documented reductions in changeover times averaging 94% (e.g. from 90 minutes to less than 5 minutes) across a wide range of companies. In SMED, changeovers are made up of steps that are termed “elements”. There are two types of elements: · Internal Elements (elements that must be completed while the equipment is stopped) · External Elements (elements that can be completed while the equipment is running) SMED (Single-Minute Exchange of Dies) is a system for dramatically reducing the time it takes to complete equipment changeovers. The essence of the SMED system is to convert as many changeover steps as possible to “external” (performed while the equipment is running), and to simplify and streamline the remaining steps. The name Single- Minute Exchange of Dies comes from the goal of reducing changeover times to the “single” digits (i.e. less than 10 minutes).
  • 8. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 8/45 The SMED process focuses on making as many elements as possible external, and simplifying and streamlining all elements. The SMED system has three major phases as shown above. These phases are performed in sequence and the entire sequence can be iterated (repeated).
  • 9. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 9/45 SMED is typically broken down into three stages. Each stage has specific tasks and objectives and all are inter-related and work together. Those stages are outlined below. Stage 1 – Separate internal and external setup Certain tasks can clearly be done before machines are stopped for changeover. These include lining up the right people, preparing parts and tools, making repairs, and bringing the parts and tools closer to the equipment. There are three practical techniques to doing this: · Develop and implement changeover checklists. · Perform function checks on parts and tools. · Reduce transportation or tools, parts, and materials. By separating these tasks and performing them as external setup can cut changeover time by as much as 30% to 50%. Stage 2 – Convert internal setup to external setup · Look at the true functions and purposes of each operation in your current internal setup · Find ways to convert these internal setups to external setup. The key to successful implementation of Stage 2 is to look at the function as if you are new to it. Three practical techniques help shift internal setup tasks to external setup. Those techniques are: · Prepare operating conditions in advance · Standardize functions · Use intermediary jigs Stage 3 – Streamline internal and external elements In this third and final stage, all of the remaining internal and external setup operations are improved. This can be done by looking closely at each operations function and purpose one more time. More specifically, Stage 3 improvements can be divided into external and internal setup improvements. Four basic approaches to accomplishing this are through: External Setup · Maintain a visual organized workplace Internal Setup
  • 10. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 10/45 at January 08, 2020 No comments: Links to this post · Implement parallel operations · Eliminate the need for adjustments · Use functional clamps · Mechanize functions SMED provides many benefits for companies and those working within the company. More specifically, the advantages of SMED along with quicker and more efficient setup times are improved flexibility, quicker delivery, better quality and higher productivity. Through these benefits you will also see simpler setups and safer changeovers, less inventory and more standardized processes. SMED advantages Reduction of the number of required tools Reducing the required inventory Reducing lead times Improved ability to produce small batches Quicker response time to customer wishes Increase capacity Increase quality Increase flexibility Reduce costs and grow profits T u e s d a y , 7 J a n u a r y 2 0 2 0 KanBan In Japanese, the word "Kan" means "visual" and "ban" means "card," so Kanban refers to visual cards
  • 11. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 11/45 The simplest Kanban board start with three columns – “Requested”, “In Progress” and “Done”. Kanban (看板) (signboard or billboard in Japanese) is a scheduling system for lean manufacturing and just-in- me manufacturing (JIT). Taiichi Ohno, an industrial engineer at Toyota, developed Kanban to improve manufacturing efficiency.
  • 12. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 12/45 at January 07, 2020 No comments: Links to this post M o n d a y , 6 J a n u a r y 2 0 2 0 Poka -Yoke What is Poka-Yoke? Poka yoke (pronounced “poh-kah yoh-kay”) comes from two Japanese words – “yokeru” which means “to avoid”, and “poka” which means “inadvertent errors.” The main objective of poke yoke is to achieve zero defects. Poka Yoke means ‘mistake-proofing’ or more literally – avoiding (yokeru) inadvertent errors (poka). Poka Yoke is any mechanism in a Lean manufacturing process that helps to avoid mistakes.
  • 13. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 13/45 Examples of Poka Yoke Application
  • 14. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 14/45 Other examples can be found in the child-proof electric sockets or the washing machine that does not start if the door is not closed properly in order to prevent flooding. These types of automation don’t allow mistakes or incorrect operation from the start. Why is Poka Yoke important? The value of using Poka Yokes is that they help people and processes work right the first time, which makes mistakes impossible to happen. These techniques can significantly improve quality and reliability of products and processes by eliminating defects. This approach to production fits perfectly the culture of continuous improvement, which is also part of the Lean management
  • 15. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 15/45 at January 06, 2020 No comments: Links to this post arsenal. When and how to use it? Poka Yoke technique could be used whenever a mistake could occur or something could be done wrong – meaning everywhere. It can be successfully applied to any type of process in manufacturing or services industry, preventing all kinds of errors: • Processing error: Process operation missed or not performed per the standard operating procedure. • Setup error: Using the wrong tooling or setting machine adjustments incorrectly. • Missing part: Not all parts included in the assembly, welding, or other processes. • Improper part/item: Wrong part used in the process. • Operations error: Carrying out an operation incorrectly. •Measurement error: Errors in machine adjustment, test measurement or dimensions of W e d n e s d a y , 1 J a n u a r y 2 0 2 0 VSM -Value Stream Mapping
  • 16. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 16/45 What is Value Stream Mapping? A map describing the flow of information and materials from supplier to customer end .It shows the current state and desired future state of processes and highlighting the gap and opportunities for improvement. How does Value Stream Mapping help? Exposes waste in the current processes and provides a roadmap for improvement through the future state. Wh t i (VSM) B fit Value Stream Mapping
  • 17. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 17/45 What is (VSM), Benefits, Process and Value To understand value stream mapping, we need to first understand what a “value stream” is. Simply put, a value stream is a series of steps that occur to provide the product or service that their customers want or need.Value stream mapping (VSM) provides us with a structured visualization of the key steps and corresponding data needed to understand and intelligently make improvements that optimize the entire process, not just one section at the expense of another. “Value stream mapping is a lean manufacturing or lean enterprise technique used to document, analyze and improve the flow of information or materials required to produce a product or service for a customer.” Value stream maps can be created for every individual product and service for every type of business.The VSM enables the team and leadership to see where the actual value is being added in the process, allowing them to improve on the overall efficiency associated with the delivery of a product or feature request.
  • 18. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 18/45 Terminology and symbols and what they mean To start, each value stream map typically has three key sections.. These sections show Information Flow, Product Flow, and a Time Ladder or Lead Time Ladder. Sections: Information Flow This section shows the communication of process-related information and the transmission of data. Product Flow This section maps the steps of the development lifecycle from concept to delivery. Time Ladder The Time Ladder provides a somewhat simplistic visual representation of the value stream timeline. Cycle time (C/T) Is the frequency of units/features produced or the average time between the completed production of one unit/feature to the completed production of the next. Setup Time (S/T)
  • 19. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 19/45 Is the amount of time needed to prepare for a given step. Uptime (%) Gives you an idea of the percentage of the total time that the processes or systems are actually active. Lead Time Is the measurement of the average amount of time needed for one feature request to make it through the entire development cycle concept to delivery, or from the beginning to ending fence post. Takt Time Is a term that is commonly used with value stream mapping. It refers to the rate at which you need to produce your products in order to meet customer demand. How will value stream mapping help? The VSM is also the most efficient way to record the current state of things. When making changes to the development cycle, creating a baseline, or Current State VSM for future comparison is the best way to go. This enables easy before-and-after comparisons of the performance data to determine if the changes made had the intended impact. Who benefits from value stream mapping?
  • 20. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 20/45 at January 01, 2020 No comments: Links to this post The real benefit to VSM is realized by the customer. The customer will experience a better-quality product, it will be delivered faster, and it will better meet their needs and expectations. T u e s d a y , 3 1 D e c e m b e r 2 0 1 9 JIT-Just-in-time Pull parts through production based on customer demand instead of pushing parts through production based on projected demand. Highly effective in reducing inventory levels Improves cash flow and reduces space requirements. Just-In-Time (JIT) What is Just-In-Time? How does Just-In-Time help?
  • 21. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 21/45 at December 31, 2019 No comments: Links to this post S u n d a y , 2 9 D e c e m b e r 2 0 1 9 OEE (Overall Equipment Effectiveness)
  • 22. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 22/45 The preferred OEE calculation is based on the three OEE Factors: Availability, Performance, and Quality. OEE is calculated by multiplying the three OEE factors: Availability, Performance, and Quality. Availability is calculated as the ra o of Run Time to Planned Produc on Time: Availability = Run Time / Planned Produc on Time Performance is the ra o of Net Run Time to Run Time. It is calculated as: Performance = (Ideal Cycle Time × Total Count) / Run Time OEE is measure of equipment effectiveness.OEE is the single best metric for identifying losses, benchmarking progress, and improving the productivity of manufacturing equipment (i.e., eliminating waste).
  • 23. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 23/45 at December 29, 2019 No comments: Links to this post Quality is calculated as: Quality = Good Count / Total Count Kaizen-Continuous Improvements Kaizen
  • 24. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 24/45 From the Japanese words “kai-” which means “change” and “-zen” which means “good” The popular meaning from Toyota is “continuous improvement” or “small incremental improvements” of all areas of a company, not just manufacturing like Cost ,Quality , Productivity , Safety , Morale A typical Kaizen event goes something like this: 1. Set goals and provide any necessary background. 2. Review the current state and develop a plan for improvements. 3. Implement improvements. 4. Review and fix what doesn’t work. 5. Report results and determine any follow-up items. This type of cycle is frequently referred to as PDCA (Plan, Do, Check, and Act). PDCA brings a scientific approach to making improvements: Plan (develop a hypothesis) KAIZEN EVENTS
  • 25. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 25/45 at December 29, 2019 No comments: Links to this post Do (run experiment) Check (evaluate results) Act (refine your experiment; then start a new cycle) S a t u r d a y , 2 8 D e c e m b e r 2 0 1 9 5S System - A place for everything & safe working place 5S BASIC
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  • 43. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 43/45 Older PostsHome Subscribe to: Posts (Atom) at December 28, 2019 No comments: Links to this post Traditional thinking dictates that you set your selling price by calculating your cost and adding on a margin for profit ... Lean Principle for Cost Reduction
  • 44. 1/16/2020 Lean Manufacturing Concepts https://leanabc.blogspot.com 44/45 Lean Manufacturing Concepts -Production Management & Technology Lean Manufacturing Concepts -Production Management & Technology Production Management ??? 1. Purpose The p... 3M-Muri,Mura and Muda (Lean Wastes) Lean Manufacturing Wastes Just what are Muda, Mura and Muri? The 3Ms of waste in Lean Manufacturing. When people think of... OEE (Overall Equipment Effectiveness) OEE is measure of equipment effectiveness. OEE is the single best metric for identifying losses, benchmarking progress, and im...
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