Lean Manufacturing - Toyota Production System

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LEAN MANUFACTURING 1

LEAN MANUFACTURING 2
Lean Manufacturing Principles and Techniques
Presented by:-
Eng. Mohammed Hamed Ahmed Soliman
Copyrig...

Content:
1. Lean Manufacturing Principles
2. Productivity Measurement, Analysis and Improvement
3. Effect & Elimination of...

LEAN MANUFACTURING 4

TOYOTA BUSINESS 5
Overview on the Toyota Performance & Business Success
Toyota’s annual profit at the end of its fisical y...

TOYOTA BUSINESS 6
The company has made a profit every year over the last 25 years and has 20$-30$ billion in its
cash war ...

TOYOTA BUSINESS 7
Toyota has the fastest product development process in the world. New cars and trucks take 12
months or l...

TOYOTA BUSINESS 8
Toyota Lexus has dominated the J.D Powers “initial quality” and long-term durability rankings
for years....

Lean Principles
LEAN MANUFACTURING 9

The five principles of lean
Lean has some goals, intentionally looking from the perspective of the
customer. The five prin...

3. Make the product flow: All obstacles that are constraining the flow of
the parts through the manufacturing processes mu...

Non-Value Added & Value-Added
Value is something that adds to the process or to the customer. Value
added is good, non-val...

TOYOTA BUSINESS 13

7 Wastes:
Commonly known in lean language as Muda “which is a Japanese term”.
It has been given a shortcut as “TIMWOOD”
T=...

For example, if there is a manufacturing process consist of several processes such as cutting,
casting, assembly, handling...

Cutting process
Lathe Process
Changeover Maintenance
Downtime
Machine Setting
Re Work Absent
Wait for
Tools
Transportation...

Takt Time
One of the most important calculations in lean is the takt time, which is
the rate of customer demand for group ...

࢚ࢇ࢑࢚ ࢚࢏࢓ࢋ =
࢟࢕࢛࢘ ࢋࢌࢌࢋࢉ࢚࢏࢜ࢋ ࢕࢖ࢋ࢘ࢇ࢚࢏࢔ࢍ ࢚࢏࢓ࢋ ࢖ࢋ࢘ ࢙ࢎ࢏ࢌ࢚
(quantity customer require per shift)
LEAN MANUFACTURING 18

Example. Takt time calculations
The effective operating time for a process is 25,200 seconds per shift.
The effective oper...

The actual intended cycle time of an assembly process, called planned
cycle time, is usually less (faster) than the takt t...

The OEE could present those interferences in terms of availability,
performance, and quality.
Many of us track pieces prod...

LEAN MANUFACTURING 22

OEE Overall Equipment Efficiency
Overall equipment efficiency (OEE) is a total productive maintenance
(TPM) module; machin...

How OEE is related to productivity and capacity?
OEE measures the ratio (%) of what product is actually made which is
defe...

OEE Metrics
OEE involves three metrics, described as follow:
1. Availability
this is a time metric that is usually measure...

2. Performance:
This is one of the most debate issues. It takes into account the factors
that are affecting the speed of t...

What is the effect of working at lower performance or speed?
Consume more resources
Waste money
Longer production lead tim...

3. Quality
This is one of the greatest wastes in the process. Quality is so important
for customers, adding value to your ...

Find: What waste time? What slow the speed? What degrades the
quality?
Production availability & time analysis
As shown in...

The above formula tends to focus on an individual process which is the
machine downtime, often caused by preventive mainte...

Productivity time
Non-Value Add
Activities
Wait for loading
Machines setting
time for changeovers
No operators
Break-times...

Performance Analysis
In many times, the primary cause of performance issues is hidden and
overlap with the availability me...

It is hard to catch the performance reasons by a software. It will require
a deep observation at the gemba.
LEAN MANUFACTU...

Quality Analysis
It is not difficult to know how many defects exist using a simple sheet to record the number of
the defec...

Code Equip description Downtime hrs
(average)
frequency Percentage
A1 Product Changeover 5 4 12.50%
A2 Maintenance downtim...

Equipment
Code
Equip
description
Downtime hrs
(average)
frequency Percentage
K1920 Cutting 7 4 17.5%
K1921 Skimming 5 6 12...

Pareto Analysis A problem solving tool that breaks data down into
manageable groups and identifies the greatest opportuni...

How to set priorities for Improvement Start?
Which machine or line to begin with? A famous question that is being
discarde...

Which problem to start with?
After reviewing the metrics details, the next question become which
problem to work on to und...

Actually, defining where to start may depend on the current culture
driven by the company. For example, if managers and di...

Gemba or genchi genbutsu
LEAN MANUFACTURING 41

Go and See to observe the real situation.
A place where the value creating works
happen.
A place where real problems solvi...

LEAN MANUFACTURING 43
Grasp the real situation at the Gemba

LEAN MANUFACTURING 44
Benchmarking is a tool
for quality analysis and
improvement

LEAN MANUFACTURING 45

1st Transportation
Transportation is about material handling. It involves all material
movements from the supplier to the ...

Factors affecting the transportation efficiency
The layout of the plant.
Distance between the different manufacturing proc...

Considerations to minimize transportation:
Mistakenly, many manufacturers tend to arrange machines by similarity
rather th...

Machines arrangement should take into consideration the following
things:
Minimizing the work in process WIP inventory
Min...

Cost effects of transportation:
Cost of the transportation equipment like forklifts.
Cost of operators driving forklifts
S...

Cost Benefit Analysis Involve in Decision Making
A common thinking that the transportation problems has no solution if the...

Toyota way of thinking about cost-benefit analysis
They believe that management decisions should be based on long-term
imp...

2nd Inventory
This is one of the greatest wastes. Inventory issues are greatly affected
by the production system. But the ...

The high inventory turns became an indication of how this organization
is profitable. You want to spend money on materials...

LEAN MANUFACTURING 55
E.g. if the cost of goods sold in the period was 1000 and the inventory
was 100, then the ITO was 10...

Cost effects of inventory: The direct cost of the inventory carrying can
be estimated through the following parameters:
1....

2. Risk:
The risk of parts deterioration and damage varies. It depends on the
product type. If this product has an expirat...

LEAN MANUFACTURING 58
Toyota are best and the leader of inventory management.
They stock parts from more than one supplier...

3. Material handling:
This is the cost of transporting goods. Some accountants see stocking
the inventory one time per yea...

5. Insurance and taxes:
Spaces need insurance, as well as the insurance for all transportation
equipment and the manpower....

WIP Inventory Hidden Costs:
Hides many issues behind it
Problems are not visible
Increase waiting between the process step...

Rocks signify quality, downtimes, and other production problems
LEAN MANUFACTURING 62

Considerations to minimize inventory
Production style affect the inventory. Pull or Push?
Building too much work in proces...

The main lean goal is to make one piece flow through the production
processes, and minimize the work in process WIP invent...

Should we have zero WIP inventory?
At the same time, having zero WIP inventory will put the process in risk of
stoppage if...

3rd Motion
This is the ergonomics. The operator needs to have his tools and parts
handed to him in exactly the right orien...

LEAN MANUFACTURING 67

Tools should be
returned after use
Someone should
follow up the board
regularly to ensure
tools are available, in
good con...

4th Waiting
This is the time waste factor,
and it involves the following
activities:
• Waiting for materials.
• Waiting fo...

When calculating the takt time, and customer demand rate, those are
the variables than need to be eliminated to improve th...

Over productivity and inventory issues are related. Over productivity
creates most of production wastes. Making product mo...

In additional, for any goods that have an expiration limitation date,
producing with mass of quantities with no realizatio...

1. The customer process (assembly process as shown in the fig)
receives some form of production instruction.
2. The materi...

The
same
machine
The
same
machine
What parts run on what machine?
LEAN MANUFACTURING 74

PatternFlexible
• Can run any part on
any process
• Many variables
• Difficult to understand
causes of problems
• Strives ...

Cost effects of over productivity: Over productivity create the most of manufacturing wastes.
Mass productivity holds many...

Traditional Mass Productivity Thinking VS Lean Thinking
One of the most debate issues is the use of mass production techni...

If a supplier process is producing with mass productivity and building
too much work in process WIP inventory, the downstr...

Large batch processing
LEAN MANUFACTURING 79

Continuous product flow
LEAN MANUFACTURING 80

With pull concept, and producing only what is needed for each process
step and between the production lines, there will be...

LEAN MANUFACTURING 82
Advantages of pull system:
Problems are surfaced quickly
Produce according to the customer needs sav...

CT=104 min CT=76 min CT=104 min CT=40 min
CT=40 min
Assembly
SawLatheDrillWeld
0.75 days
WIP
0.25 days
WIP
1.7 days
WIP
0....

CT=105 minCT=103 min
CT=108 min
Weld
0.13 days
WIP Inventory
Min= 0
Max= 1
Lead times=0.80 days
Saw, Lathe, Drill
Assembly...

Before After
Production Lead Time 3.75 days 0.8 days
# of forklifts 11 1
Travel Distance per
product piece
1700 ft. 1000 f...

6th Over processing
It means making more steps in the process than what are actually
needed or making steps that are not n...

Many processes can be improved and reduced time through removal of
the unnecessary steps. The improvement is not only limi...

TOYOTA BUSINESS 88
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LEAN MANUFACTURING 89

Mapping as a lean tool for process improvement
LEAN MANUFACTURING 90

What is Mapping? it is a range of techniques for analyzing the steps (or
stages) in process. Any process is suitable. As e...

Is Lean a Positive or Just an Extra Work?
The company/Managers/Engineers need to decide carefully whether to
spend their c...

•Basic Process Mapping
•The Big Picture Map
•Capacity Maps
•Value Stream Mapping ”VSM”
•Value and Capacity Stream Map
•Swi...

LEAN MANUFACTURING 94

•Value Stream Maps.
The non value added and the value added are being separated in the map, time of each is
calculated and...

LEAN MANUFACTURING 96

Toyota Production Goals
Zero Defects
100 percent value added
One-Piece Flow, in sequence, on demand
Security for people
LE...

LEAN MANUFACTURING 98
Phase#1 Preparation for the Kaizen Event
1. Clearly define the scope of work
2. Set the objectives: ...

Define the Customer
Requirements
Current State Map
Future State Map
Implementation Plan
Do it
Evaluate
-Scope of Business
...

1.Analyze Current-State MAP
To complete this map you need the following:
• Team should physically walk through the process...

LEAN MANUFACTURING 101
• Point out the value added, the pure non-value added, and the
required non-value added
• Calculate...

Process Actual/Current Best Possible
(Target)
Data Box (KPIs)
Each task/process is presented with the current measurement ...

LEAN MANUFACTURING 103
Parking lot
Process Actual/Current Best Possible
Those are the tasks that you decided to work on la...

Process Map Analysis “Red Post-its Analysis”.
Process /issue
description
Symptom/Problem Exists Total time
LEAN MANUFACTUR...

2.Develop a Future State Vision/Future State Map
This is the waste free map that has no waste in time or resources with
th...

LEAN MANUFACTURING 106
This map would include:
• The optimum lead time (cycle time) of each task in the process
• The opti...

3.Implementation & Visual Tracking System
The use of the visual tracking system on field during the kaizen work and
before...

LEAN MANUFACTURING 108
Metric Unit of
measure
Target Improvement Owner
Process Cycle time Days/hours
Non-value added %
Val...

Value Stream Mapping is a tool to ensure that process improvement
effort:
1. Fit together from a process to process so tha...

LEAN MANUFACTURING 110
Inappropriate actions commonly performed by lean leaders when using
the value stream mapping for re...

LEAN MANUFACTURING 111
• Jump to the do phase to implement the plan without spending
enough time gathering facts, colletin...

Productivity & capacity improvement through finding the bottleneck
Machine.1 Machine.2
Capacity=100 units per hour Capacit...

Sustain Standardize
Shine
Sort Set in Order
LEAN MANUFACTURING 113

Any successful 5S process must achieve the following:
Eliminate the seven deadly wastes from the process
Reduce ergonomics...

LEAN MANUFACTURING 115
A place for everything, and everything in its place

LEAN MANUFACTURING 116

7 to 8 out of each 10 lean projects fail as companies try to treat lean as
toolkit, copying and pasting the techniques wit...

Toyota’s main pillars “4P”
LEAN MANUFACTURING 118

LEAN MANUFACTURING 119
Eng. MohammedEng. MohammedEng. MohammedEng. Mohammed Hamed AhmedHamed AhmedHamed AhmedHamed Ahmed S...

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