2. What is LEAN MANUFACTURING??
“The production of goods using less
of everything by reducing ‘waste’ and
increasing value added activity”
3. ORIGIN
Lean Manufacturing is sometimes called the
Toyota Production System (TPS) because
Toyota Motor Company’s Eiji Toyoda and
Taiichui Ohno are given credit for its
approach and innovations
4. “Key” Lean Manufacturing Techniques
1. Elimination of waste
2. 5s
3. JIT/Pull production system
4. Cellular Manufacturing
5. KANBAN
5. What is Waste?
• Waste is anything that
happens to a product that
does not add value from the
customer’s perspective
• Products being stored,
inspected or delayed,
products waiting in queues,
and defective products do
not add value
6. The 8 wastes
Introduction to ‘TIM WOODS’
T – Transport
I – Inventory
M – Movement
W – Waiting
O – Over-processing
O – Over-production
D - Defects
S - Skill
9. JIT/Pull system
• JIT literally means Just In Time.
• It aims to produce only what is needed, when
it is needed.
• Production is pulled by the downstream
workstation so that each workstation should
only produce what is requested by the next
workstation.
• One-piece flow is key implementation which
means that parts are moved through
operations from step-to-step with no WIP in
between either one piece at a time or a small
batch at a time.
11. Cellular manufacturing
1.In Functional Manufacturing similar machines
are placed close together (e.g. lathes, millers,
drills etc.).
2.In Cellular Manufacturing systems machines
are grouped together according to the
families of parts produced.
3.The major advantage is that material flow is
significantly improved, which reduces the
distance travelled by materials.
14. KANBAN
A system of continuous supply of components
and parts such that workers have what they
need, where they need, when they need it
KANBAN is the process through JIT is
achieved
16. Key Implications of lean
manufacturing
Traditional Lean
Orientation Supply driven Customer driven
Planning Orders are
pushed though
factory based on
production
plan/forecast
Orders are pulled
through factory
based on
customer/downst
ream demand
Batch size Large small
Quality
inspection
Checking of
samples by QC
inspectors
In-line inspection
by workers
Inventory Buffer of work-
in-progress
Little or no work-
in-progress
17. Advantages
• Increased overall productivity
• Reduced amount of floor space required
• Reduced manufacturing lead time
• Improved flexibility to react to changes
• Improved quality
• Less inventory
• Increases working standards
• Increases worker talents
18. Disadvantages
• Success of lean requires the
full commitment and
involvement of all employees.
• Long term commitment
required (i.e. workers should
give full support to apply
lean)
