Lean manufacturing mitramatra

LEAN
MANUFACTURING
Principles, Tools &
Methods

I’M DANANG
I feel happy to be able to share
something with you, again
.
2
• Today, I’m senior business development in SGS Indonesia.
• Since year 2004 – I have been IATF Automotive auditor
• Previously I worked in Astra Daihatsu Motor (1995 – 2003)
• I have Six Sigma Master Black Belt in year 2001
• My frist job experience in Dirgantara Indonesia – Inc. (IPTN) for
N250 project for following period :1992 – 1995.
Copyright 2020 © DWI

MY REFERENCES
There is a lot of reference material in
this world, and besides the experience
that I've done - I use the following
references :
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• Toyota Production System: Practical Approach to Production
Management – by Yasuhiro Monden
• Japanese Manufacturing Techniques Nine Hidden Lessons In
Simplicity - Richard J. Schonberger
• http://insights.btoes.com/resources/lean-manufacturing-principles-
lean-tools-introduction-
• Lean Manufacturing: Principles, Tools and Methods by Bosch Group
• Recon®gurable manufacturing systems: Key to future
manufacturing - M. G. MEHRA B I , A . G . ULSOY and Y. KOREN
Department of Mechanical Engineering and Applied Mechanics, The
University of Michigan, Ann

WHAT IS LEAN
MANUFACTURING
The theory of lean manufacturing
has been built on the Toyota
Production System which was
initially learnt from the Ford’s
Production System
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THEPRODUCTIONPHILOSOPHIESHAVE
TOEVOLVEWITHNEWINNOVATIONSDUE
TOTECHNOLOGICALADVANCEMENTAND
UNLIMITEDDEMANDSOFCUSTOMERS
5
• The theory of lean manufacturing has been built on the Toyota Production System
which was initially learnt from the Ford’s Production System.
• Therefore, the production philosophy and basic management principles adopted by the
Toyota Production System and the Ford’s Production System can be recognized as the
fundamental theories contributed to the development of lean manufacturing philosophy

THE MEANING OF
LEAN MANUFACTURING
Lean manufacturing is a systematic
method for the elimination of waste
("Muda") within a manufacturing system.
Lean also takes into account waste created
through overburden ("Muri") and waste
created through unevenness in work loads
("Mura").
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THE MEANING OF
LEAN
MANUFACTURING
This concept focuses on key
processes of manufacturing
systems and improves the
organizational performance in
financial and non-financial terms.
Lean manufacturing is about
doing more with less; it involves a
never-ending effort to reduce
waste and non-value-added
International Journal of
Economics, activities.

CONTINUES
FLOW
Next product can be
introduced to the process
as soon as the one before
has completed step one.
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ONE-PIECE /
CONTINUOUS FLOW
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The antithesis to 'batch' production,
continuous flow manufacturing is the
process of keeping a product moving from
the beginning of production to the
completion of the product.
It is used in manufacturing to maximise
efficiency against 'batching

FLEXIBILITY WITH
SIMPLICITY
The line could be a
simple line – for
flexibility
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PROCESSDESIGNBASICS:
•CONTINUOUSFLOW
•SAVEFACTORYFLOORSPACE
•NOEXCESSPRODUCTION
•NOEXTRASHELF/DRAWER SPACE
• Since continuous-flow, one-at-a-time
manufacturing is another goal of lean
manufacturing, it is important that each
workstation or machine be designed to
fit within a minimal envelope.
• No WIP – process will done in one
continues Flow
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TAKT TIME
Takt time is the rate at which
the finished product needs to
be completed, in order to
meet the customer demand.
Outside of Lean, the term
references the german word
for a Baton used to keep a
tempo, or a 'heartbeat'

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HEIJUNKA
Heijunka is a Japanese technique for achieving a perfect supply
and demand balance. In other words, achieving an even output
flow by carefully coordinating very small production batches across
the whole manufacturing line. Heijunka means ‘leveling.’ When
done correctly, it helps organizations meet demand elegantly, i.e.,
without haste. They meet demand while also reducing waste in the
production process
Simplicity is possible with Hiejunka
Ohno (1988) : “The slower but consistent tortoise
causes less waste and is much more desirable than
the speedy hare that races ahead and then stops
occasionally to doze”

WORKPLACE
ORGANIZATION
An efficiently organized
workplace is the most
fundamental step to
guaranteeing the organization
productivity and preparing it
for major expansions in the
future.
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WORKPLACE
ORGANIZATION
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Workplace Organization
Basics:
• Organize tools with appropriate tool
holders
• Provide back-up tools at automatic
stations
• Insist on flexible tool mounting
structures
• Put the right information where it’s
needed

WORKPLACE
ORGANIZATION
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Benefits:
• Minimize downtime
• Reduce wasted motion,
• Uninterrupted workpiece
flow
• Improve quality
• Flexibility

COMPONENT
VISUAL CONTROL
An efficiently organized
workplace is the most
fundamental step to
guaranteeing the organization
productivity and preparing it
for major expansions in the
future.
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COMPONENT VISUALMANAGEMENT
• One Piece Flow Supply parts as needed
• Parts loaded from outside the cell
• Use gravity feed as the preferred method
• FIFO parts presentation
• Flexibility support
• Error assembly detection capability
The benefits :
Easy reconfiguration, reduce wasted
motion, uninterrupted production, quick
changeover

EASY TO CHANGE
RECONFIGURABILITY
must be rapidly designed, able
to convert quickly to the
production of new models,
able to adjust capacity
quickly, and able to integrate
technology and to produce an
increased variety of products
in unpredictable quantities.
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RECONFIGURABLE
MANUFACTURING SYSTEMS:
KEYTOFUTUREMANUFACTURING
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• Changing manufacturing environment
characterized by aggressive competition on a
global scale and rapid changes in process
technology requires to create production systems
that are themselves easily upgradable and into
which new technologies and new functions can
be readily integrated
• New approach must be rapidly designed, able to
convert quickly to the production of new models,
able to adjust capacity quickly, and able to
integrate technology and to produce an increased
variety of products in unpredictable quantities.

ZERO DEFECT
QUALITY
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ZDQZERODEFECTQUALITY
2
2
• Theory ensures that there is no waste
existing in a project. Waste refers to all
unproductive processes, tools, employees
and so on. Anything that is unproductive and
does not add value to a project should be
eliminated, called the process of elimination
of waste.

JIDOKA
AUTOMATION WITH HUMAN
TOUCH
"intelligent automation" or "Automation with a
human touch". This type of automation
implements some supervisory functions rather
than production functions. At Toyota, this usually
means that if an abnormal situation arises; the
machine stops and the worker will stop the
production line. It is a quality control process
that applies the following four principles:[2]
Detect the abnormality. Stop. Fix or correct the
immediate condition. Investigate the root cause
and install a countermeasure.
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MAINTAINABILITY
Long down times cannot be
tolerated in a pull-through
system. When customer
demand exists, the product
must be produced..
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MAINTAINABILITY
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Maintainability Basics:
• Ease of service
• Manual back-up
• Put the operator manual on the machine
• Standardize as many components as
possible
• Use common tools and fixtures
• No finish work required on system
components.
• Minimum spare parts necessary
Benefits:
Minimum down time, easy-to-source
replacement parts, quick service

SIMPLE
CONSTRUCTION
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SIMPLE
PRODUCTION LINE
• All controls or fixtures positioned with
ergonomics in mind
• All serviceable components at rear of
machine/workstation to eliminate Interference of
maintenance personnel with production
• Clearance for all tools for ease of use
• All guards easy to remove with
• simple hand tools
Benefits:
• Minimum down time, easy serviceability,
• optimum ergonomic design.

WORKING
ENVIRONMENT
Productivity will achieved
with effective working
environment - Any properly
designed lean work cell must,
by definition, be good working
environment designed.
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WORKING ENVIRONMENT
FOR LEAN
MANUFACTURING
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Create Value
Value is one of the fundamental lean concepts that
underpins everything else. Before attempting to
streamline processes or reduce waste, it’s vital to
understand the customer value that your
organization is striving to deliver.
It’s also important to ensure that this defined value
is aligned with client needs.
This is where the magic happens but unfortunately
for many companies, this doesn’t always occur as
readily as they’d like.

HYBRID SYSTEMS
FOR
LEAN
MANUFACTURING
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In keeping with the flexibility requirement
for lean manufacturing, there may be
times when a hybrid system rather than a
pure lean system is best for the
manufacturing Process
Hybrid manufacturing systems combine
the economies of the lean system with
the safety and efficiency of an automated
Final Considerations: Hybrid Systems
system.

ACTION FOR CALL
Kalau anda merasa belum terlalu
jelas dan butuh bantuan – layangkan
kepada kami
THANK
YOU
Danang Widoyoko
+62 811196211
danangwid1987@gmail.com
bersamamitramatra@gmail.com

Lean manufacturing mitramatra

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