Sample presentation

1. “LEAN MANUFACTUING-CONCEPT,
LIMITATION, APPLICATIONS: AN
OVERVIEW”
Submitted By
Ms. PUNAM NIVRUTTI PATIL
DPGD/OC13/1243
SPECIALIZATION: OPERATIONS
WELINGKAR INSTITUTE OF MANAGEMENT DEVELOPMENT & RESEACH
AUGUST 2015

2. INTRODUCTION
• Lean manufacturing- A way to eliminate waste & improve efficiency in
manufacturing environment.
• Lean was generated from just in time(JIT) Philosophy of continuous &
forced problem solving.
• Lean is the fundamental way that many of the world’s best companies do
business.
• It is the production of goods using less everything compared to traditional
mass production.

4. FORMS OF WASTE
• Muda- Any form of
waste in process
• Muri- Unreasonable
burden on people or
machines
• Mura- Waste created
through unevenness

6. GOALS
Improve Quality
Reduce total costs
Reduce Time
Zero accidents
Zero inventory

7. LEAN MANUFACTURING PROCESS
Identify waste
Analyze the
waste & find
the root cause
Solve the root
cause & repeat
the cycle

8. TOOLS
• 5 S
• Andon
• Bottleneck Analysis
• Continuous flow
• Gemba
• Heijunka
• Hoshin kanri
• Jidoka
• Just In Time
• kaizen
• Kanban
• Key performance indicator
• Overall equipment effectiveness
• PDCA
• Poka Yoke
• Root cause analysis
• SMED
• Takt time
• Total productive maintenance
• Value stream mapping
• Visual factory

9. Some of important tools
5 S
• Clearing (Seiri)
• 2. Organizing (Seiton)
• 3. Cleaning ( Seiso)
• 4. Standardization (Seiketsu)
• 5. Discipline & Training (Shitsuke)
Just In Time
• The ideal just in time facility would
carry zero finished goods and build
them only when they are ordered
kaizen
• Kaizen simply means "change for
better“
• The Toyota Production System is
known for kaizen

10. KANBAN
• The basic concept of a kanban is a hand
sized card that moves with the product or
material.
• There are two basic classifications of
kanbans; generic and brand.
• Within the two classifications there are
two main types of kanbans; production
kanbans and move kanbans
Total Productive
Maintenance
TPM (Total Productive Maintenance) is a
holistic approach to equipment
maintenance that strives to achieve
perfect production:
 No Breakdowns
 No Small Stops or Slow Running
No Defects
In addition it values a safe working
environment:
 No Accidents

11. KEY IMPLICATIONS OF LEAN MANUFACURING
Traditional Batch Manufacturing Lean Manufacturing
Orientation Supply driven Customer driven
Planning Orders as pushed through factory
based on production plan / forecast
Orders are pulled through factory
based on customer / downstream
demand
Inventory Buffer of work in progress between
each production stage
Little or no wok in progress
between each production stage
Handoff of work in process Material after each stage
accumulate into work in progress
stage areas before being retrieved
by next production stage
Material handed of directly from
one production stage to next
Production cycle time Longer than actual time Shorter

12. LIMITATIONS
• Supply Problems
• High cost of implementation
• Lack of acceptance by employees
• Customer dissatisfaction problems
• New inefficiencies
• Problems in Just In Time (JIT)
• Worker frustration
• Over focus on waste
• Over focus on present
• Lack of standard methodology

13. APPLICATIONS
• In process industries
• In financial service sector
• In emergency department
• In construction industries
• In pharmaceutical industries
• In public

14. Toyota Production
System
TPS has three desired outcomes:
• To provide the customer with the
highest quality vehicles, at
lowest possible cost, in a timely
manner with the shortest
possible lead times.
• To provide members with work
satisfaction, job security and fair
treatment.
• It gives the company flexibility to
respond to the market, achieve
profit through cost reduction
activities and long-term
prosperity.

15. CONCLUSION
Lean manufacturing is:
“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”.