2. What is lean?
Lean is a way of thinking. It is a philosophy. Everybody has some mind blocks.
These mind blocks put constraint on thinking ability of people. Doing more and
more with less and less human effort, less equipment, less time and while
coming closer and closer to providing customers with exactly what they want”.
The another definition of lean Production can be defined as an adaption of mass
production in which workers and work cells are made more flexible and efficient
by adopting methods that reduce wastes in all forms. Lean tools and
methodology focuses basically towards removal of wastes. Different types of
wastes and tools of lean are being used. Lean manufacturing represents the
cultural at all levels of the company.
3. Features of lean production
• Management philosophy
• “Pull” system though the plant
WHAT IT IS
• Attacks waste
• Exposes problems and bottlenecks
• Achieves streamlined production
WHAT IT DOES
• Employee participation
• Industrial engineering/basics
• Continuing improvement
• Total quality control
• Small lot sizes
WHAT IT REQUIRES
• Stable environment
WHAT IT ASSUMES
4. History
Ford: Design for manufacturing
Start with an article that suits and then study to find some way of
eliminating the entirely useless parts. This applies to everything— a shoe,
a dress, a house, a piece of machinery, a railroad, a steamship, an
airplane. As we cut out useless parts and simplify necessary ones, we also
cut down the cost of making. ...But also it is to be remembered that all
the parts are designed so that they can be most easily made."
Ohno-put ideas into practice systematically
“When bombarded with questions from our group on what inspired his
thinking, Ohno just laughed and said he learned it all from Henry Ford's
book."
5. TPS:Toyota production system
A system that continually searches for and eliminates
waste throughout the value chain.
Views every enterprise activity as an operation and
applies its waste reduction concepts to each activity -
from Customers to the Board of Directors to Support Staff
to Production Plants to Suppliers
6. Types of waste
Overproduction – Producing more materials than is needed, before is needed
is the fundamental waste in lean manufacturing.
Defects – Defective products impede flow and leads to wasteful handling,
time and effort.
Inventories – Material sits taking up space, costing money,and potentially
being damaged. Problems are not visible.
Motion – Any motion that does not add value to the product is waste.
Over Processing – Extra processing not essential to value-added from the
customer point of view is waste.
Transportation – Moving material does not enhance the value of the product
to the customer.
Waiting – Material waiting is not material flowing through value-added
operations.
7.
8. Tools And Techniques
Cellular Manufacturing – A cell consists of equipment's and workstations that
are arranged in order that maintains smooth flow of materials and
components through the process. It also has assigned operators that are
trained and qualified to work at the cell.
Just In Time – It is the management idea to eliminate sources of
manufacturing wastes by producing the right part in the right place in the
right time. As the name indicates it means to produce just in time of
requirement. It is the basis of pull system. It addresses the wastes such as
work in process inventory, defects.
Standardization of Work – A very important principle of waste elimination is
standardization of worker actions. Standardize work basically ensures that
each job is organised and is carried out in most effective manner. No matter
who is doing the job the same level of quality must be achieved.
9. Kaizen – It is another fundamental principle of lean which is Japanese word
for continuous improvement. One of the most effective tool of continuous
improvement is 5S. 5S is modular step towards serious wastes reduction. 5s
consists of Japanese words Seiri (sort), Seiton (straighten), Seiso (sweep and
clean), Seiktsu (systemize) and Shitsuke (standardize). It means change for
betterment.
Pokayoke – It is a Japanese word for mistake proofing. If we go on proofing
mistakes means we are ultimately improving continuously
10. Elimination of waste
Acronym-CLOSED MITT
Complexity
Labor
Overproduction
Space
Energy
Defects
Materials
Inventory
Time
Transportation
11. Elimination of waste
1. Group technology
2. 5S
3. JIT production
4. Quality at the source
5. Kanban production control system
6. Minimized setup times
7. Uniform plant loading
8. Focused factory networks
14. Minimizing wastes 5s
“Good factories develop beginning with the 5S’s. Bad
factories fall apart beginning with the 5 S’s.”
- Hirouki Hirano
15. JIT Just in time
Only produce what’s needed
The opposite of “Just In Case” philosophy
Ideal lot size is one
Minimize transit time
Frequent small deliveries
Pro’s
•Minimal inventory
•Less space
•More visual
•Easier to spot quality issues
Con’s
•Requires discipline
•Requires good problem solving
•Suppliers or warehouses must be close
•Requires high quality
16. Quality at the source
“Do it right the first time”
Call for help
Immediately stop the process and correct it vs. passing it on to
inspection or repair
17.
18. Kanban
Signaling device to control flow of material
• Cards
• Empty containers
• Lights
• Colored golf balls
• Etc
19. Setup Time
Long setup times drive:
Long production runs
Large lots
Long lead times
JIT requires small lots and minimum kanbans
Setup reduction
Focused efforts
Problem solving
Flexible equipment
20. Respect the people
Level payrolls
Cooperative employee unions
Subcontractor networks
Bottom-up management style
Quality circles (Small Group Problem Solving)
21. 4 Rule
1. All work shall be highly specified as to content,
sequence, timing, and outcome
2. Every customer-supplier connection must be direct, and
there must be an quick yes-or-no way to send requests
and receive responses
3. The pathway for every product and service must be
simple and direct
4. Any improvement must be made in accordance with the
scientific method, under the guidance of a teacher, at
the lowest possible level in the organization
22. Lean Implementation
Empowered Workforce
Problem Solving
Performance Measurement
Total Quality
Management
Flow
Process
Stable
Schedule
Kanban
Pull
Involved
Suppliers
Continual Inventory
Reduction
Product
Design
23. Summary and Conclusion
Lean Production is the set of activities that achieves
quality production at minimum cost and inventory
The flow of material is pulled through the process by
downstream operations
Lean originated with the Toyota Production System and its
two philosophies – elimination of waste, and respect for
people
CLOSED MITT forms of waste
