Lean manufacturing is a systematic method for waste minimization ("Muda") within a manufacturing system without sacrificing productivity.http://www.vpresentationslides.com/lean-manufacturing-ppt/

1. Seminar
On
“Lean Manufacturing”
Prepared By: Guided By:
www.vpresentationslides.com
www.vpresentationslides.com

2. Lean Manufacturing Definition
Lean has been defined in many different ways.
“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.”
By The MEP Lean Network

3. History Timeline for Lean Manufacturing

4. Lean manufacturing is a philosophy
In 1990 James Womack, Daniel T. Jones, and Daniel Roos
wrote a book called “The Machine That Changed
the World: The Story of Lean Production-- Toyota's
Secret Weapon in the Global Car Wars That Is Now
Revolutionizing World Industry”
In this book, Womack introduced the Toyota Production
System to American.
What was new was a phrase–
"Lean Manufacturing."

5. Muda (Waste)
Taiichi Ohno (1912-1990), the Toyota executive who was the most
ferocious foe of waste human history has produced, identified the first
seven types of muda in manufacturing system:
• Storage
• Transportation
• Waiting
• Motion
• Process
• Defects
• Over-production
Muda is everywhere.

6. Lean Overview

7. Lean Manufacturing Tools
 5S
 Value Stream Mapping
 Standardized Work
 Production Leveling
 Kaizen
 Kanban
 Visual Workplace
Single-Minute Exchange of Die
Poka-yoke
One-piece flow
Cellular Manufacturing

8. Production Planning System (Push System)

9. Push or Pull?
A push system

10. Push or Pull?
A pull system

11. Kanban Operation
WK(2)PK(1) PK(i+1)PK(2) PK(N)WK(1) WK(N)WK(i+1)WK(i) PK(i)
RM FG
Kanban Stage
1
Kanban Stage
i
Station
1
Station
2
Station
i
Station
i+1
Station
N+1
Figure 3.3. A kanban stage formed by two adjacent stations.
From stage i-1 To stage i+1
1
2
i
3
Kanban Stage
i
i +1
WKPK
4
K
K-1
5

12. Finished
goods
Raw materials inventory
Semi-finished
parts
PKPK PK WKWKWK
Station 1 Station 2
Station 3
Semi-finished parts
Material
handler Order
receiving
RMRMRM
14
3
2
1
3
4
4
5
6
7
7
7
7
8
8
9
12
13
13
11
10
11
11
11

13. Current State Map of A Case Study Example

14. Future State Map
At which stations, are parts withdrawn?
At which stations, are parts scheduled?

15. The Objections to Lean
How should you deal with these objections to lean?
•“It is very hard to deal with raw material suppliers if
we fully depend on customer order.”
•“It takes too much discipline.”
•“It takes too long to implement.”
•“My process is too complex; I have to deal with too
many uncontrollable variables, like late supplier
shipments, sick people, etc.”
•“My process requires a large batch size.”
•“It doesn’t make sense in my industry.”
•“It’s unclear to me how lean will work with my MRP
system.”

16. Key Steps in Transforming
a Company to the Lean Approach
1. Establish a steering team—conduct strategic planning session
2. Train the steering team and the model line team in the disciplines of
lean
3. Perform PQR (product-quantity-routing) analysis
4. Identify value streams—select a value stream
5. Calculate model line takt time
6. Value stream map the model line—assemble current state map
7. Balance the line—assign standard work
8. Establish standard WIP (inventory levels)
9. Test the system (virtual cell)—document results
10. Setup reduction event

17. Key Steps in Transforming
a Company to the Lean Approach
11. Conduct 5S event—apply TPM techniques
12. Establish visual signals—reduce paperwork
13. Explore alternative flow patterns
14. Develop block layout
15. Develop detailed layout
16. Execute move
17. Select next value stream and repeat
Gary Conner, President of Lean Enterprise Training, Newport, OR, Road Map to Lean for
the Smaller Shop, Society of Manufacturing Engineers, Lean Manufacturing 2007,
Supplement to Manufacturing Engineering, 2007. pp. 27-29.

18. References
• https://en.wikipedia.org/wiki/Lean_manufacturing
• https://en.wikipedia.org/wiki/Lean_manufacturing#History
• Society of Manufacturing Engineers, Lean Manufacturing 2007,
Supplement to Manufacturing Engineering, 2007.
• Society of Manufacturing Engineers, Lean Manufacturing 2008,
Supplement to Manufacturing Engineering, 2008.

19. THANK YOU
www.vpresentationslides.com