This presentation introduces lean manufacturing and identifies the eight types of waste. Lean manufacturing aims to eliminate waste through continuous improvement. The eight types of waste are overproduction, over processing, rework, waiting, excess inventory, excess motion, excess transportation, and disconnection of staff skills. Specific examples are provided for each type of waste along with potential causes. Steps for waste elimination include motivation, just-in-time processes, correct automation, leveled scheduling, balanced workloads, quality inspection, line balancing, forecasting, and communication. Tools for waste reduction include visual controls, quick changeovers, cellular manufacturing, and total productive maintenance.
Value" is any action or process that a customer would be willing to pay for. Lean manufacturing is a management philosophy focused on the reduction of the "seven wastes in" order to improve overall customer value.
This is a little presentation we used for our hourly employees when we rolled out lean. Not attached are the real life examples we discussed as part of the training.
This presentation will help you identify waste in your environment. Reducing these wastes from your life will give you more time and freedom for more important things which matter to you in your life.
Value" is any action or process that a customer would be willing to pay for. Lean manufacturing is a management philosophy focused on the reduction of the "seven wastes in" order to improve overall customer value.
This is a little presentation we used for our hourly employees when we rolled out lean. Not attached are the real life examples we discussed as part of the training.
This presentation will help you identify waste in your environment. Reducing these wastes from your life will give you more time and freedom for more important things which matter to you in your life.
The 8 waste in Lean Manufacturing - Lean Six Sigma TrainingAnkit Sharma
Waste is any step or action in a process that is not required to complete a process (called “Non Value-Adding”) successfully. When Waste is removed, only the steps that are required (called “Value-Adding”) to deliver a satisfactory product or service to the customer remain in the process.
In any business, the greatest enemy of profitability is waste-- typically of time or money. In lean manufacturing, waste is any expense or effort that is put forward which does not transform raw materials into an item the customer is willing to pay for. There are 8 types of waste in Lean Manufacturing. Seven of the eight wastes are production process oriented, while the eighth waste is directly related to management’s ability to utilize personnel.
“Lean” is a management philosophy based on the Toyota Production System (TPS). With Lean Manufacturing, you will be able to enhance value for your customers by improving and smoothing the process flow and eliminating waste. Simply put, with Lean, you will be able to increase productivity and create greater customer value with less resources.
By teaching this presentation, managers and employees will have a better understanding of the Lean principles and approach to eliminating waste, and will be more forthcoming to lead and participate in the Lean implementation process.
LEARNING OBJECTIVES
1. Acquire knowledge on the key concepts and principles of Lean
2. Describe the common Lean methods and tools for waste elimination and value creation
3. Describe the key roles in Lean deployment
4. Define the success factors for sustaining a Lean culture
CONTENTS
1. Introduction to Lean Manufacturing
2. Key Concepts of Lean
3. Lean Methods & Tools
4. Lean Roles
5. Sustaining a Lean Culture
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
The 8 waste in Lean Manufacturing - Lean Six Sigma TrainingAnkit Sharma
Waste is any step or action in a process that is not required to complete a process (called “Non Value-Adding”) successfully. When Waste is removed, only the steps that are required (called “Value-Adding”) to deliver a satisfactory product or service to the customer remain in the process.
In any business, the greatest enemy of profitability is waste-- typically of time or money. In lean manufacturing, waste is any expense or effort that is put forward which does not transform raw materials into an item the customer is willing to pay for. There are 8 types of waste in Lean Manufacturing. Seven of the eight wastes are production process oriented, while the eighth waste is directly related to management’s ability to utilize personnel.
“Lean” is a management philosophy based on the Toyota Production System (TPS). With Lean Manufacturing, you will be able to enhance value for your customers by improving and smoothing the process flow and eliminating waste. Simply put, with Lean, you will be able to increase productivity and create greater customer value with less resources.
By teaching this presentation, managers and employees will have a better understanding of the Lean principles and approach to eliminating waste, and will be more forthcoming to lead and participate in the Lean implementation process.
LEARNING OBJECTIVES
1. Acquire knowledge on the key concepts and principles of Lean
2. Describe the common Lean methods and tools for waste elimination and value creation
3. Describe the key roles in Lean deployment
4. Define the success factors for sustaining a Lean culture
CONTENTS
1. Introduction to Lean Manufacturing
2. Key Concepts of Lean
3. Lean Methods & Tools
4. Lean Roles
5. Sustaining a Lean Culture
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
Agile software development has proven to be more successful than traditional methods. However there are many Agile methodologies (Scrum, Kanban, Lean, XP). It is difficult to make a right choice.
Do you want to know the differences between Scrum and Lean? Perhaps you struggle with your existing Scrum implementation and looking for a better methodology. So did I. I spent many hours looking for continuous improvement beyond Retrospectives and Sprint Reviews. And I found my answer in applying Lean Principles.
This session will help you to increase your understanding of Lean and Scrum. It will also give you some practical examples of implementing Lean in Scrum teams.
I used this presentation at a kickoff meeting at one of our other sites. I had worked with the management team to define their Hoshin Plan prior to this and we wanted to share it with the plant.
4. lean manufacturing
A systematic approach to identifying and
eliminating waste (non value added
activities ) through continues improvement
by flowing the product at the pull of
customers in pursuit of perfection.
Lean is a term to describe a system that
produces what the customers want ,when
they want it , with minimum waste.
6. objectives of lean manufacturing
Elimination of waste in following areas:
1.Extra Work force.
2.Outsourcing.
3.Overtime.
4.Air shipment.
Mostly used in production based factory management
7. Waste
Waste is anything that does not contribute to
transforming a part to the customer’s needs.
Essentially, a “waste” is anything that the customer is
not willing to pay for.
8. action for reDucing Waste
1.Waste can be 100% eliminated
2.Waste can be reduced or simplified
9. TYPEs OF WAsTE
8 types of waste
01. Overproduction
02. Over processing
03. Rework
04.Waiting
05. Excess inventory
06. Excess motion
07. Excess transportation
08. Disconnectivity
10. OVER PRODUCTION
Running a machine to produce product that is not
needed for next process.
Means making more than is required by the next
process, making earlier than is required by the next
process or making faster than is required by the next
process.
12. OVER PROCEssING
Doing more work than necessary to meet the customer
needs or requirements
Doing more detailed information than necessary
Sometimes it is keep busy work
13. CAUsEs OF OVER PROCEssING
Product change without process changes
Lack of communications
Raw material approvals
Rely on paper and extra copies
14. REWORK
Means any repair or additional work performed outside
the operators normal work.
Reworks are-
Pieces of needles in product
Fabrics non adequate to specifications
Wrong size or fit
Pieces cut wrong
Incorrect information
Drawn incorrectly
15. CAUsEs OF REWORK WAsTE
Weak processes control.
Poor quality.
Unbalanced inventory level.
Deficient planed maintenance.
Inadequate education or training.
Customer needs not understood.
16. WAITING
Any idle time which is not spent for performing
work for goods or services
It may be-
for the next product
for the materials
for the assistant
for equipments
for information
17. CAUSES OF WAITING
Times Unbalanced work load
Unplanned maintenance
Long process set up
Upstream quality problem
Unleveled scheduling
18. ExCESS INvENTOry Or WIP
• Material between operations due to large lot
production or processes with cycle time.
• Material sits taking up space, costing money and
potentially being damaged.
• It may be-
Raw materials in storage
Materials and supplies in storage.
Materials at the process
Finished goods stored prior to shipping.
19. CAUSES OF ExCESS INvENTOry Or
WIP
Product complexity
Unleveled scheduling
Unbalanced work load
Unreliable shipments by suppliers
Misunderstood communications
20. ExCESS mOTION
Any motion that does not add value to the product is
waste
Motion of the workers, machines, and transport(due to
the inappropriate location of tools and parts )
It may be-
Walking from point to point during the
work cycle.
Reaching to pick materials.
Turning or bending.
Matching parts.
Repeat evacuation motion.
Excessive travel distance.
21. CAUSES OF mOTION WASTE
Poor people ,machine effectiveness.
Inconsistent work methods.
Unfavorable facility or cell layout.
Poor workplace organization and house keeping.
Extra “busy” movements while waiting.
22. ExCESS TrANSPOrTATION
WASTE
Moving the materials which does not enhance the
value of the product to the customers.
It may be-
The movement of materials, weather manual
or automatic.
Moving materials to and from the
warehouse. movement of materials at the process.
Handling and carrying paper work between
operations.
23. CAUSES OF ExCESS
TrANSPOrTATION WASTE
Poor plant layout.
Poor understanding of the process flow for
production.
Large batch size
Long lead time.
Large storage areas
24. UNdEr UTIlIzING PEOPlE Or
dISCONNECTIvITy.
It means that not taking advantages of peoples
abilities.
25. Causes of disConneCtivity
Old guard thinking , politicies , the business culture.
Poor hiring practices.
Low or no investment on training.
Low pay , high turn over strategy
26. funCtion of waste
reduCtion
Labor utilization-
to maximize labor working time.
Machines utilization-
to maximize machines needles
downtime.
Space utilization-
to reduce cost related to WIP,
Inventories
27. steps for waste elimination
Motivation
Follow the “Just In Time” manufacturing process.
Use correct automation
Schedule will be leveled
Balanced workload
Appropriate quality inspection.
Proper line balancing
Well market forecast
Communication will be very good between
management level and workers.
28. waste reduCe tools
Maintain 5S.
Visual control systems.
Quick change over.
Cellular manufacturing by team work.
Total Productive Maintenance.
Kanban.
Kaizen .
Mistake proofing.
