Pre-Presentation on Lean Manufacturing by Irfan Sahito from Dawood University Of Engineering & Technology Karachi.

1. FINAL YEAR PROJECT PRE-PRESENTATION
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2. INTRODUCTION
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3. PROJECT GROUP
MEMBERS
INTERNAL SUPERVISOR ENGR. G.M.
KHAN
EXTERNAL SUPERVISOR ENGR. ZAHID
HUSSAIN MANAGER AT DAWLANCE KHI
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IRFAN SAHITO D-12-IN-309
ABDUL REHMAN D-12-IN-310
IRFAN KHAKI D-12-IN-321
SYED MOHSIN D-12-IN-341

4. IMPLEMENTATION
OF
LEAN MANUFACTURING TECHNIQUES
AT
DAWLANCE (PVT) LIMITED
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5. CONTENTS:
 1 ABOUT DAWLANCE
 2 WHAT IS LEAN MANUFACTURING
 3 WHAT IS WASTE
 4 TYPES OF WASTE
 5 MUDA, MURA, MURI
 6 PRINCIPLES OF LEAN MANUFACTURING
 7 METHODOLIGIES OF LEA MANUFACTURING
 8 BENEFITS OF 5S
 9 CONCLUSION
 10
 QUESTIONS & ANSWERS
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6. About
 Dawlance is a leading manufacturer of house hold appliances in
Pakistan.
 It was established in 1980
 7th most favorite brand of Pakistan
 Deals in three departments:
Food Care
Fabric Care
Home Care
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7. Food
Care
Refrigerators Freezers
Fabric
Care
Washing
Machine
Dryers
Home
Care
Air
conditioners
Inverter
Series
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8. What is Lean Manufacturing?
• Lean Manufacturing – A way to eliminate waste and improve
efficiency in a manufacturing environment
• Lean focuses on continuous flow, the value stream and eliminating
muda, the Japanese word for waste
• Lean manufacturing is the production of goods using less of
everything compared to traditional mass production: less waste,
human effort, manufacturing space, investment in tools, inventory,
and engineering time to develop a new product
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9. What is Waste?
Waste is defined as anything that does not add
value to the final product.
Products being stored, inspected or delayed,
products waiting in queues, and defective products
do not add value.
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10. TYPES OF WASTE
1. Over production
2. Waiting
3. Inventory
4. Transportation
5. Inappropriate processing
6. Excess motion or ergonomic problems
7. Defected products
8. Underutilization of employee
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11. OVERPRODUCTION
Producing more than the customer
orders or producing early. Inventory of
any kind is usually waste.
WAITING
Workers having to stand around waiting
for the next processing step, tool, part
etc. Or no work because of stock-outs, lot
processing delays, equipment downtime,
and capacity bottlenecks.
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12. Carrying WIP long distances, creating
inefficient transport, or moving parts in
and out of storage facility.
TRANSPORTATION
Inventory may be in the form of raw
materials, work-in-progress (WIP),
finished goods, obsolescence, or
damaged goods
INVENTORY
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13. Taking unneeded steps to process the
parts. Inefficient processing due to
poor tools and product design, causing
unnecessary motion and producing
defects
INAPPROPRIATE PROCESSING
EXCESS MOTION
Any wasted motion employees have to
perform during the course of their
work, such as looking for, reaching for,
or stacking parts, tools etc. Walking is a
waste.
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14. Production of defective parts or
correction. Repair or rework, scrap,
replacement production, and inspection
mean wasteful handling, time and
efforts.
DEFECTED PRODUCT
UNUSED EMPLOYEE CREATIVITY
Losing ideas, skills, improvements, and
learning opportunities by not engaging
or listening to your employees.
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15. Activities that are wasteful, primarily caused by lack of
communication and not understanding the system or the
purposes and goals of the organization
MUDA
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16. Unevenness, excessive burdening of people or machinery.
If a standard procedure is not followed, there’s a tendency
for different results to be generated for a single activity or
step.
MURA
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17. MURI
The word stands for unreasonable, overburden, or
absurdity, most likely due to inadequate skills, poor
planning, under estimation, or poor task schedules, leading
to inconsistent production, inefficient stops and starts.
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19. 1. Specify what creates value from the customer’s perspective
2. Elimination of Waste
3. Continuous Improvement
4. Respect For Humanity
5. Leveled Production
6. Just In Time Production
7. Quality Built In
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20. METHODDOLOGIES OF LEAN MANUFACTURING
• Five “S”
• Error proofing (Poka-Yoke)
• Just In Time
• Kanban
• Quick Changeover or SMED
• Work leveling – Heijunka
• Kaizen
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21. FIVE S (5 S)
5S is a technique that results in a well-organized
workplace complete with visual controls and order.
• Sort (Seiri)
• Set in order (Seiton)
• Shine (Seiso)
• Standardize (Seiketsu)
• Sustain (Shitsuke)
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22. BEFORE AFTER
EXAMPLE
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23. • Improve safety
• Decrease down time
• Raise employee morale
• Identify problems more quickly
• Develop control through visibility
• Establish convenient work practices
• Increase product and process quality
• Strengthen employees’ pride in their work
• Promote stronger communication among staff
BENEFIT OF 5’S’
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24. JUST IN TIME
The idea behind JIT is that parts are produced or moved only
when needed and in the quantity required. The ideal just in
time facility would carry zero finished goods and build them
only when they are ordered.
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25. Dawlance is a well-known household appliance company, seeks to improve
its manufacturing processes and desires to produce quality products which
can become wow for the customers.
Although the processes are very accurate and up to the mark but still there
are some problems which we have observed and discussed above.
The overall experience is that the staff members of Dawlance are quite
cooperative, caring and confident. The really appreciating thing is the
obedience of rules and regulations prescribed by the company.
CONCLUSION
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