This document provides an overview of lean systems and lean manufacturing. It defines key lean concepts like identifying and eliminating waste, continuous improvement, and value from the customer perspective. Lean aims to systematically identify and remove non-value activities. The document also discusses lean tools and techniques, the Toyota Production System approach, benefits of lean, and the history of lean management.

1. By Solomon Tilahun
Course name: Lean system

2. • Lean refers creating more value for customers
through identifying, eliminating or reducing
waste.
• Lean is a way of thinking. It it is all about
continuous improvement with a focus on
eliminating all forms of waste in a process.
What is Lean?
Customer
value

3. • Value is A capability provided to a customer at
the right time at an appropriate price, as defined
by the customer.
•Cost
•Quality
•Delivery
What is value?

5. • Lean is systematic approach to identify and eliminating
the waste (non value activities) through continuous
improvement.
Lean manufacturing

6. • Lean Manufacturing is all about making a product
in the most efficient and effective manner, while
looking for ways to continuously improve.
• Continuous Improvements:
– Decrease Cycle Time
– Eliminate sources of waste in a process
– Increase Throughout
Continued…..

7. what makes a manufacturing system Lean?
The 3 m’s of lean
Muda____Waste
Mura____Inconsistency
Muri___unreasonableness

10. • 1950 to 1890
• Eli Whitey is most famous for perfection of interchangeable
parts. Whitney developed this about 1799.
• As production system or system changed; few people
concerned themselves with:
What happened between processes?
How multiple processes where arranged within the factory?
How each worker went about a task?
This changed in the late 1890’s with the work of early
industrial engineers.
History of lean management

11. • Prepare power point on the following history of
lean management.
– 1850-1890--- Eli Whitney
– 1878--frederick W. Taylor
– 1904—Frank Gilbreth
– 1908—Henry Ford
– 1945 to 1970 ---Ishikawa, Edwards Deming
– 1949 to 1975--- Shigo, ohno
– 1980—Omark industries , & Kawasaki
– 1990 to today---industrial engineers
Assignment 1

12. • Lean provides tangible benefits
• Reduces costs not just selling price
– Reduces delivery time, cycle time, set-up time
– Eliminates waste
– Seeks continuous improvement
• Improves quality
• Improves customer ratings and perceptions
• Increases overall customer satisfaction
• Improves employee involvement, morale, and
company culture
• Helps “transform” manufacturers
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Benefits

13. Toyota Production System (TPS)
• Quality, Cost, Delivery
– Shorten Production Flow by
Eliminating Waste
• Just In Time
– The Right Part at the Right Time in
the Right Amount
– Continuous Flow
– Pull Systems
– Level Production
• Built-In Quality
– Error Proofing – Poka Yoke
– Visual Controls
• Operational Stability
– Standardized Work
– Robust Products & Processes
– Total Productive Maintenance
– Supplier Involvement

14. Lean manufacturing tools
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15. • The Japanese word for waste is muda, which is
defined as “uselessness.”
• Lean tools are designed to reduce Muda in
organizations and improve quality control.
• In other words, Lean tools seek to eliminate
processes that aren’t valuable.
What Are Lean Tools?

17. Lean Tools Summary
Bottleneck Analysis Structured way of looking at workflows
Just-in-Time (JIT) On-demand system of production
Value Stream Mapping Analyzing and optimizing a process
Overall Equipment Effectiveness
(OEE)
Measure of productive time
Plan-Do-Check-Act (PDCA) Method to manage change
Error Proofing Analysis tool based on prevention
Root Cause Analysis (RCA) Method to get the foundation of an issue