Introduction to Lean Manufacturing

1. Lean Manufacturing

2. What is Lean?
 No “Fat”
 Streamline flow
 Optimized process
 Promotes Value Add
 Reduces
 Cost
 Lead time
 A philosophy?
 A process?
 An end result?
 Continuous
improvement
 “Good enough is not
good enough”

3. What Is Lean?
 Lean is basically all about getting the right
things, to the right place, at the right time, in the
right quantity while minimizing waste and being
flexible and open to change.
 More importantly, all of these concepts have to
be understood, appreciated, and embraced by
the actual employees who build the products
and therefore own the processes. The cultural
aspect of lean is just as important as the actual
tools or methodologies.

4. What Is Lean?
 Lean Thinking is a mindset
 Lean is about REMOVING WASTE, and
increasing customer value.
 Lean is about smooth process flows, doing only
those activities that add customer value and
eliminating all other activities that don’t.
 "Lean" comes from the ability to achieve more
with less resource, by the continuous elimination
of waste.

5. Lean Manufacturing – a paradigm to get morefrom less
Lean manufacturing aims at improving systems and practices
to deliver more and better value with lesser
inputs and considers use of resources for any goal other than
creation of value for customer as undesirable and to be wasteful and,
therefore, a target for elimination
What Is Lean?

6. Lean Manufacturing is a systematic way to deliver the :
 highest quality,
 lowest cost products with the
 shortest lead-times through the
 relentless elimination of waste.”
Defining Lean
Lean manufacturing is simply a continuously
progressive way of producing what the customer
wants, when they want it, at a price they are prepared
to pay and using least resources.

7. Purpose of Lean
 The purpose of Lean Manufacturing is to make your
company strong and fast.
 Strong = High performance, repeatable performance
 Fast = Easily adapts to fluctuations in market conditions
Reduced operating costs and improved customer
satisfaction are natural by-products of being Lean

8. • Specify value from the standpoint of the end customer by
product family. ('Specify what creates VALUE from the
customer's perspective )
Define Value from
the Customer
Perspective
• Identify all the steps in the value stream for each product
family, eliminating whenever possible those steps that do not
create value.(Identify all the steps across the whole value
stream supply chain, from raw materials to finished goods)
Identify the value
stream
• Make the value-creating steps occur in tight sequence so the
product will flow smoothly toward the customer , Make those
actions which create value flow
Make the process
flow
• Make only what the customer has ordered
Pull from the
customer
• Strive for perfection by continually removing successive
layers of waste
• Lean is all about respecting people while eliminating the 3
M’s which are muri (overburdening), mura (unevenness),
and muda (non value added activity).
Head toward
Perfection
5 Principles of Lean

9. Defining Lean (Considering Lean Principles
)
A systematic approach to identifying and eliminating
waste (non-value-added activities) through continuous
improvement by flowing the product at the pull of the
customer in pursuit of perfection.”
Non-value added is an
activity that takes time,
resources or space, but
does not add to the
value of the product or
service itself.
Value-added is an activity
that transforms or shapes
raw material or information to
meet customer requirements.
Waste: Anything that adds Cost to the product without
adding Value

10. OrderProcessing, Transport, Storage, Waiting,
Rework, Machine Setup, Inspection, Machine
Breakdowns, etc...
It means :
- Eliminating work processes that add no value
to the product
- Simplify those processes that add value
RUN
TIME
Total Lead Time
Typically >95% of Total Lead Time is Non-Value Added!!
The Basics of Lean Manufacturing

11. Lean – What Does It Mean?
Value Chain ConsumersSuppliers
Reduce Lead Time
Better
service
Less
stocks
Less
cost
Higher
flexibility
Improved
Morale
Reduced
Complexity
Eliminate Non Value Added activities
Maximizing flow of customer “value” by eliminating waste , variability and fatigue

12. 12
Lean – What Does It Mean?
After
(non value
add) Wait
Time
Work Time
(value add)
• Cost
• Defects
• Lead Time
• Inventory
• Space
• Waste
• Productivity
• Customer Satisfaction
• Profit
• Customer
Responsiveness
• Capacity
• Quality
• Cash flow
• On time delivery
Cycle Time
Before
Same work
Completed in
Least time

13. Lean = Eliminating Non Value
Activities
5%
95%
VALUE ADDED NON VALUE ADDED

14. L E A N
LEAST EFFORTS ARE NEEDED
To Brief Lean : We Define

15. Concept of Lean Manufacturing
Eliminate
MUDA
Eliminate
MURA
Eliminate
MURI
CREATE
VALUE

16. 16
Central Theme of Lean
MUDA
MURA
MURI
Non Value Added Activities,
waste & waiting
Inconsistent, Irregular or
uneven use of person or
machine
Physical Strain
and Overburden

17. Muda, Muri , Mura
 Muri and Mura lead to Muda
Example : 12 tons of material to be shipped in a 4 ton-truck
X 2 = Overburden Two 6-ton
trips
X 6 = Waste Six 2-ton
trips
= Unevenness
MURI
MUDA
MURA
No
MURI
The three ‘MU’s avoided X 3 = No
MUDA
No
MURA

18. The Original Seven Mudas (Wastages)
Acronym :-T.I.M.W.O.O.D
1. Transportation
2. Inventory
3. Motion
4. Waiting
5. Overproduction/ Excess
6. Over Processing
7. Defects
Later an eighth waste described as Underutilized People/ Non Utilized Skill /
Tallent
.

19. 7 Wastes + 1 Deadly
Waste of Lean
We define as DOWNTIME
D
• Defect
O
• Over Processing
W
• Waiting
N
• Non Utilized Talent
T
• Transportation
I
• Inventory
M
• Motion
E
• Excess Production

20. Ashutosh Mishra
+91 8765653833