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![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]](https://image.slidesharecdn.com/aleanmanufacturingmc-240319143646-8c00a606/75/Lean-Manufacturing-5S-3M-Advantages-of-Lean-Manufacturingng-3-2048.jpg)
Lean Manufacturing, 5S, 3M, Advantages of Lean Manufacturingng
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- 2. Lean Manufacturing Content Lorem ipsumdolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore
- 3. Genesis of Lean Manufacturing LeanManufacturing • “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 thisbook, 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 TimeManufacturing 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.
- 6. JIT manufacturing is very similarto Lean manufacturing, and the terms are often used synonymously.
- 7. 3M'S • Lean manufacturingis 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.
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- 9. • Waste isbroadly 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 .
- 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
- 12. The 5 S’sof Lean • Seiri (sort, necessary items) • • •Seiton (set-in-order, efficient placement) • • •Seison (shine or sweep, cleanliness) • • •Seiketsu (standardize, cont. improvement) • • •Shitsuke (sustain, discipline)
- 13. Steps of Implementing LeanManufacturing 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 toolsused 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
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