Lean Manufacturing is a production methodology focused on maximizing efficiency and minimizing waste in manufacturing processes. It originated from the Toyota Production System (TPS) and is characterized by principles such as continuous improvement (Kaizen), just-in-time production, and respect for people.
The goal of Lean Manufacturing is to deliver maximum value to customers with minimal waste, including excess inventory, overproduction, defects, and unnecessary motion or processing steps. By implementing Lean principles, companies can achieve higher productivity, lower costs, better quality, and greater flexibility in responding to customer demands.
2. Lean Manufacturing
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3. Genesis of Lean
Manufacturing
Lean Manufacturing
• “Perfection is not attainable. But if
we chase perfection, we can catch
excellence.” Vince Lombardi
• Lean manufacturing or lean
production are reasonably new terms that
can be traced to Jim Womack, Daniel Jones
and Daniel Roos’ book, The Machine that
changed the world [1991]
4. Toyota Production
System
In this book, the authors examined the
manufacturing activities exemplified by the Toyota
Production System. Lean manufacturing is the
systematic elimination of waste.
This manufacturing system was initially developed by
Taiichi Ohno in the 1950s as the successor to Henry
Ford’s mass production system.
https://www.youtube.com/watch?v=psTNv1blsCU
5. Just in Time Manufacturing
JIT MANUFACTURING HELPS
ORGANIZATIONS CONTROL VARIABILITY
IN THEIR PROCESSES, ALLOWING THEM
TO INCREASE PRODUCTIVITY WHILE
LOWERING COSTS.
Since it involved making products x only
when needed from materials that were
made available by suppliers only as required,
just-in-time (JIT) became its generic name.
7. 3M'S
• Lean manufacturing is a Japanese method focused on
3M’s. These Ms are:
• muda, the Japanese word for waste,
• mura, the Japanese word for inconsistency,
• muri, the Japanese word for unreasonableness.Muda
specifically focuses on activities to be eliminated.
9. • Waste is broadly defined as anything that adds
cost to the product without adding value to it.
• Lean production is about expanding capacity
by reducing costs and shortening cycle times
between order and ship date .
10.
11. Kaizen (Ky’zen)
• “Kai” means “change”
• “zen” means “good (for the better)”
• Gradual, orderly, and continuous
improvement or Ongoing improvement
involving everyone.
• The three pillars of Kaizen include
housekeeping, waste elimination, and
standardization
13. Steps of Implementing
Lean Manufacturing
1. Identify what constitutes
value to the customer
2.Indication of a
sequence of operations
defined as a value stream
3.Creation of a flow of
activities - operations
4. Allowing the customer
to "pull" products or
services from the
process
5.Streamlining the
process
14. The primary tools used in Lean
implementation are
• Nested structure of the manufacturing process
• Kanban system
• Process mapping
• Reduction of equipment changeover times
• 5S methodology and visualization of activities
and their results
• ZQC (zero quality control) system
• Total productive maintenance (TPM)
• Freedom from disruption
• flow
• Rhythm
• Pull Production
15. Benefits of Lean
Manufacturing
• Reduces costs not just selling price
• Reduces delivery time, cycle time, set-up time
• Eliminates waste
• Seeks continuous improvement
• Improves quality
• Improves customer ratings and perceptions
• Increases overall customer satisfaction
• Improves employee involvement, morale, and
company culture
• Helps “transform” manufacturers