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    Lean Manufacturing: Presented by Vineeta Kanwal ID No. 44316

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    Vineeta Kanwal
    Lean manufacturing aims to maximize value and minimize waste in production processes. It evolved from craft manufacturing, which produced high quality goods in small batches but was very expensive, and mass manufacturing, which standardized production to reduce costs but sacrificed quality. Lean manufacturing combines the advantages of both by using less of everything compared to mass production, including human effort, equipment, time and space. This is achieved through identifying and eliminating waste using tools like just-in-time production, continuous improvement processes, and visual management systems. Implementing lean principles can provide benefits like reduced costs, improved quality, increased productivity and customer responsiveness.

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    Lean Manufacturing: Presented by Vineeta Kanwal ID No. 44316

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    Vineeta Kanwal
    214 views35 pages
    Lean manufacturing aims to maximize value and minimize waste in production processes. It evolved from craft manufacturing, which produced high quality goods in small batches but was very expensive, and mass manufacturing, which standardized production to reduce costs but sacrificed quality. Lean manufacturing combines the advantages of both by using less of everything compared to mass production, including human effort, equipment, time and space. This is achieved through identifying and eliminating waste using tools like just-in-time production, continuous improvement processes, and visual management systems. Implementing lean principles can provide benefits like reduced costs, improved quality, increased productivity and customer responsiveness.

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    Lean manufacturing aims to maximize value and minimize waste in production processes. It evolved from craft manufacturing, which produced high quality goods in small batches but was very expensive, and mass manufacturing, which standardized production to reduce costs but sacrificed quality. Lean manufacturing combines the advantages of both by using less of everything compared to mass production, including human effort, equipment, time and space. This is achieved through identifying and eliminating waste using tools like just-in-time production, continuous improvement processes, and visual management systems. Implementing lean principles can provide benefits like reduced costs, improved quality, increased productivity and customer responsiveness.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    214 views35 pages

    Lean Manufacturing: Presented by Vineeta Kanwal ID No. 44316

    Uploaded by

    Vineeta Kanwal
    Lean manufacturing aims to maximize value and minimize waste in production processes. It evolved from craft manufacturing, which produced high quality goods in small batches but was very expensive, and mass manufacturing, which standardized production to reduce costs but sacrificed quality. Lean manufacturing combines the advantages of both by using less of everything compared to mass production, including human effort, equipment, time and space. This is achieved through identifying and eliminating waste using tools like just-in-time production, continuous improvement processes, and visual management systems. Implementing lean principles can provide benefits like reduced costs, improved quality, increased productivity and customer responsiveness.

    Copyright:

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    Download as PPT, PDF, TXT or read online from Scribd
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    of 35

    Lean Manufacturing

    Presented By Vineeta Kanwal ID No. 44316

    Contents
    History of lean manufacturing Craft manufacturing Mass manufacturing Lean manufacturing Definition of lean manufacturing Lean thinking How does lean work? Who is lean applicable for?

    Contd
    What makes a manufacturing system lean? Waste Principles of lean manufacturing Tools of lean manufacturing Economics Advantages Disadvantages Future scope Summary References

    History of Lean Manufacturing

    Craft Manufacturing
    Late 1800s Car built on blocks in the barn as workers walked around the car Built by craftsmen with pride Components hand-crafted, hand-fitted Excellent quality Very expensive Few produced

    Mass manufacturing

    Assembly line - Henry Ford 1920s

    Low skilled labor, simplistic jobs, no pride in work


    Interchangeable parts Lower quality Affordably priced for the average family Billions produced - identical

    Lean manufacturing
    Combines the advantages of craft & mass manufacturing It uses less of everything compared to mass production Interchangeable parts, even more variety Excellent quality mandatory Costs being decreased through process improvements.

    Contd
    The material moves faster through the system
    Business as Usual

    Customer Order

    Waste Time

    Product Shipment

    Lean Manufacturing

    Customer Order

    Waste

    Product Shipment

    Time (Shorter)

    Definition of lean manufacturing


    The production of goods using less of everything by reducing waste and increasing value added activity

    If it doesnt add value, it adds cost!


    Lean manufacturing evolved out of lean thinking which means removal of waste

    Lean thinking
    Powerful antidote to muda Lean thinking is lean because it provides a way to do more and more with less and less

    Human effort Equipment Time Space

    Coming closer and closer to providing customers with exactly what they want Create new work rather than simply destroying jobs in the name of efficiency

    How does Lean work?


    Considers an end to end value stream that delivers competitive advantage. Seeks fast flexible flow. Eliminates/prevents waste (Muda). Extends the Toyota Production System (TPS).

    Who is Lean applicable to?


    Lean is principally associated with manufacturing industries but can be equally applicable to both service and administration processes. Currently it is also being adopted by the food manufacturing and meat processing sectors. Its not a new phenomenon, Japanese auto manufacturers have been developing Lean for over 50 years.

    What makes a manufacturing system lean? the 3 Ms of lean


    Muda waste Mura - inconsistency Muri - unreasonableness

    Waste
    Anything that adds cost to the product without adding value Seven wastes Overproduction- making in excess of demand Waiting- delay between processing steps Transportation- unnecessary transport of materials

    Contd
    Over processing- doing more than is necessary Inventory- more WIP than the absolute minimum Movement- unnecessary motion of people during the course of their work Defectives- products not meeting customer requirements

    Principles of lean manufacturing

    Specify value Identify the value stream Make product flow/Make value creating steps flow Let the customer pull product Strive towards perfection

    Specify value
    Critical starting point for lean thinking Specify what creates value from the customers perspective Value must be defined in terms of specific products at specific prices at specific times Define the Target Cost

    Identify the value stream

    The value stream is the set of all specific actions required to bring a specific product Purpose of value stream mapping is to identify waste Map the current state and the future state All value streams have internal and external components

    Make product flow


    Make the remaining, value-creating steps of the process flow Redefine the work of functions, departments, and firms Create single piece flow instead of batch processing Ensure positive contribution to value creation

    Let the customer pull product


    Response to the customers rate of demand Let the customer pull the product from you as needed rather than pushing products, often unwanted, onto the customer The demands of the customer become more stable when they know then can get what they want right away Pull system is more responsive to changes then push systems

    Strive towards perfection


    By continually attempting to produce exactly what the customer wants. The journey of continuous improvement. Producing exactly what the customer wants, exactly when, economically. Perfection is an aspiration, anything and everything is able to be improved.

    Tools of lean manufacturing

    TQM - A management philosophy which seeks to integrate all organizational functions ( marketing, finance, design, engineering, production, customer service.) to focus on meeting customer needs and organizational objectives.

    JIT - Just-in-time (JIT) is an inventory strategy implemented to improve the return on investment of a business by reducing in-process inventory and its

    Contd

    KAIZEN- focus upon continuous

    improvement of process It aims to eliminate waste


    Single Minute Exchange of Dies (SMED)-

    Eliminates setup errors Increases safety Reduces the cost of setups Reduces waiting times and inventory buildups

    Contd

    5S SEIRI:- Sorting SEITON:- Simplifying SEISO:- Sweeping, systematic cleaning or shining SEIKESTSU:- Standardizing SHITSUKE:- Sustaining Increases organization and efficiency Avoids wasted motion Increases safety Eliminates unnecessary inventory Offers improvements at an inexpensive cost

    Contd

    Six sigmaThe term six sigma comes from the field of statistics. Six Sigma approach has broadened to include such things as programme and project management tools and rules all of which are complementary to lean manufacturing

    Contd
    Kanban A system that uses replenishment signals to simplify inventory management Signals (usually cards) hold product details Cards stay attached to a bin that holds the product When bin is empty, it is returned to the start of the assembly line for replenishment Full bins are returned to the customer,

    Contd

    Cellular manufacturing
    Dividing the manufacture of products into semi-autonomous and multi-skilled teams known as work cells Simplifies material flow and management Reduces interdepartmental travel Reduces lot sizes Simplifies scheduling

    Contd

    Process mapping
    Biggest tool in lean all others are deployed from mapping output
    Establishes real priorities by those who do the work action plans with names & dates

    Dramatic short & medium-term results


    Idea generation & team involvement in decision making

    Economics

    Reduction of Inventory Reduced Waste Increased market share Increased competitive advantage

    Advantages

    Low production cost Supports green manufacturing Shorter cycle times Reduction in overhead / operating costs Productivity increases (30% - 40%) Increase Profit Customer Lead Time Reductions (50% +) Work in Process Inventory reductions (70%+) On Time Delivery to customers (95% +) Quality Performance Improvements

    Disadvantages

    Difficulty involved with changing processes to implement lean principles Long term commitment required Very risky process - expect supply chain issues while changing over to lean

    Future scope

    Lean manufacturing in the 22nd century needs a more structured blending with analytics and the identification of improvement projects so that the enterprise as a whole benefits Lean needs a formal integration structure with predictive scorecards and analytically/innovatively determined strategies

    Summary

    Greatest impact on companys inventory flow and order distribution Cornerstone of Lean is the Toyota Production System. The greatest obstacle to the waste's removal is usually failure to recognize it. Lean manufacturing includes techniques for recognition and removal of the waste.

    References

    Approaches and practices of lean manufacturing: The case of electrical and electronics companies, Yu Cheng Wong and Kuan Yew Wong (2010) A case study of lean, sustainable manufacturing, Geoff Miller, Janice Pawloski, Charles Standridge (2010) Integrated production machines and systems beyond lean manufacturing, D.T. Pham and P.T.N. Pham, A. Thomas (2008) An evaluation of the value stream mapping tool, Lasa IS, Laburu CO, Vila R (2008) The effectiveness of lean manufacturing audits in driving improvements in operational performance, Patrick Taggart (2009) Fundamentals of CAD/CAM/CIM, Vikram Sharma

    THANK YOU

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