The document discusses Lean Production principles including eliminating waste, simplifying procedures, and speeding up production. It describes the seven types of waste targeted in Lean (overproduction, waiting, transportation, inventory, motion, over-processing, defective products). Benefits of Lean include reducing costs, lead times, inventory, and increasing quality and flexibility. Additional Lean tools discussed include Kaizen (continuous improvement), Poka-Yoke (mistake proofing), Kanban (pull system), and Jidoka (quality at source).

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LEAN Production
Md. Shafiul Alam Chowdhury
tanzeem772@gmail.com

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Lean Production
• Less time, inventory, space, labor, and money
• eliminating waste, simplifying procedures and speeding
up production.
• also known as Toyota Production System
• Toyota was able to greatly reduce leadtime and cost
using the TPS (Toyota Production System), while
improving quality at the same time

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Lean Production
Systematic elimination of the 7 types of waste:
• Overproduction
• Waiting
• Transportation
• Inventory
• Motion
• over-processing,
• defective products
The japanese call it Muda (in Eng: Wastage)

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Benifits
• Waste reduction by 80%
• Production cost reduction by 50%
• Manufacturing cycle times decreased by 50%
• Labor reduction by 50% while maintaining or
increasing throughput
• Inventory reduction by 80% while increasing
customer service levels

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Benifits
• Capacity in current facilities increase by 50%
• Higher quality
• Higher profits
• Higher system flexibility in reacting to changes
in requirements improved
• More strategic focus
• Improved cash flow through increasing shipping
and billing frequencies

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Kaizen
• philosophy of continual improvement
• involving everyone – managers and workers
Management has two major components:
• maintenance, and
• improvement

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Poka-Yoke
• defect warning system
• make it impossible to make mistakes
• initial term was baka-yoke, which means
‘fool-proofing’
• improve quality and reliability
• can eliminate both human and
mechanical errors

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Kanban
• to achieve Just-in-time
• pulls just the number and type of
components the process requires
• physical card or other devices

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Kanban card

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Jidoka
• meaning “automation with a human
touch”
• quality control process
• four principles:
• Detect the abnormality
• Stop
• Fix or correct the immediate condition
• Investigate the root cause and install a
countermeasure

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Jidoka
• Jidoka involves the automatic detection of
errors or defects during production
• helps to detect a problem earlier and avoids
the spread of bad practices

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The End