Scribd
Upload
72 views

Lean Overview

Lean manufacturing aims to shorten the time between a customer order and product shipment by eliminating waste. It focuses on reducing defects, inventory levels, transportation, waiting times, overproduction, excess processing, and motion. Common lean tools include 5S, value stream mapping, just-in-time production, continuous flow, and pull systems to optimize efficiency and maximize value delivered to customers. Implementing lean principles can reduce costs by 10-30% through eliminating activities that do not create value from the customer's perspective.

Uploaded by

Sanjib Biswas
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
72 views

Lean Overview

Lean manufacturing aims to shorten the time between a customer order and product shipment by eliminating waste. It focuses on reducing defects, inventory levels, transportation, waiting times, overproduction, excess processing, and motion. Common lean tools include 5S, value stream mapping, just-in-time production, continuous flow, and pull systems to optimize efficiency and maximize value delivered to customers. Implementing lean principles can reduce costs by 10-30% through eliminating activities that do not create value from the customer's perspective.

Uploaded by

Sanjib Biswas
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 23

Lean Manufacturing An

Overview

Lean
Half the hours of human effort in the factory
Half the defects in the finished product
One-third the hours of engineering effort
Half the factory space for the same output
A tenth or less of in-process inventories
Source:
The Machine that Changed the
World
Womack, Jones, Roos 1990

LEAN is not a bolt on technique, more a way of life


leading to new thinking and a total change in culture.
11/10/15

Lean Manufacturing
It is a manufacturing philosophy which shortens the time line between
the customer order and the product shipment by eliminating waste.
Business as Usual

Customer
Order

Waste

Product
Shipment

Time
Lean Manufacturing

Customer
Order

Waste

Product
Shipment

Time (Shorter)
11/10/15

Lean thinking
The basics of Lean Thinking is the customer first
How do we do that?
By creating thinking people
And how do we do that?
By creating workplaces that are more human and
encourage people to think

Who wants what...


WORK

value creation

waste

Cash
Cash!!!!

Customer
Low Cost
High Quality
Availability

Value
Value!!!!
Your Company
Profit
Repeat Business
Growth

Waste is anything that does not add value to product or service.


11/10/15

Cost of Non-Quality
Researches across the world suggest that cost of non-quality can go up as
much as 10% - 30% of gross turnover of a manufacturing organization
depending on size and complexity. In other words, if we could implement lean
management in an organization through deploying techniques of value stream
mapping and waste reduction, the bottom-line may enhance by as much as
30% of the organizations turnover.
11/10/15

TRANSITION OF QUALITY, COST & PROFIT


Cost per Unit
6

Quality
4

Lesser down time


Lesser rework
Lesser customer complaint
Lesser leakages
Lesser paper work

Quality

Profit
per Unit

Cost of nonquality could be


as high as 10%30% of firms
revenue

11/10/15

Preventing Poor Quality (Comparison)


Prevention Costs

Appraisal Costs

Repair Costs

Failure Costs
Internal
External

Benefit

Prevention Costs

Appraisal Costs
Repair Costs
Failure Costs

Before Quality
Cost Alignment

11/10/15

After Quality Cost


Alignment

Types of Work Identifying Waste


Value
ValueAdding
Adding(VA):
(VA):
Any
activity
that
directly
Any activity that directly
adds
addsvalue
valuetotothe
theproduct
product

Incidental
IncidentalWork
Work(NVA),
(NVA),
but
unavoidable
with
but unavoidable withcurrent
current
technology
or
methods.
technology or methods.
Any
Anywork
workcarried
carriedout
outthat
thatdoes
does
not
increase
product
value
not increase product value
Waste
Waste
An
An activity
activity that
that does
does not
not add
add
value
to
the
product
and
hence
value to the product and hence
something
something that
that you
you dont
dont want
want
to
to be
be doing,
doing, hence
hence Waste.
Waste.

11/10/15

11

Focus on Waste

11/10/15

13

7 Forms of Waste
DEFECT
WAITING

Repair or
Rework

Any non-work time


waiting for tools,
supplies, parts, etc..

OVER PROCESSING
Doing more work than
is necessary

Types
of
Waste

INVENTORY
Maintaining excess
inventory of raw matls,
parts in process, or
finished goods.

11/10/15

MOTION
Any wasted motion
to pick up parts or
stack parts. Also
wasted walking

OVERPRODUCTION
Producing more
than is needed
before it is needed

TRANSPORTATION
Wasted effort to transport
materials, parts, or
finished goods into or
out of storage, or
between
processes.

14

Waste of Overproduction
If you make more product than is required by
the next process, make it earlier than is
required by the next process, or make product
faster than is required by the next process, you
overproduce.
Extra inventory

Extra handling
Extra space

Waste of
Overproduction
Extra interest
charges
Extra paperwork

Extra people

Extra defects
Extra overhead
15

Waste from Waiting times


Operator or machine idle

time.

Causes of Waiting Waste


Unbalanced work load & unlevel scheduling
Unplanned maintenance
Long process set-up times
Upstream quality problem.

16

Waste of Transportation
Transporting parts and

materials around the plant


without adding value
Causes:

Poor plant layout


Poor understanding of the
process
flow for
production
Large batch sizes, long lead
times, and large storage areas.

17

Processing Waste
Effort that adds no value to the product or

service from the customers viewpoint

Causes:
Product changes without process changes
True customer requirements undefined
Over processing to accommodate downtime

18

Inventory Waste
Maintaining excess inventory of raw
materials, parts in process, or
finished goods.
Causes of excess inventory
Protects the company from
inefficiencies and unexpected
problems.
Product complexity
Unbalanced workload, unleveled
scheduling
Poor Market forecast
Unreliable shipments by suppliers
19

Waste of motion
Any movement of
people or machines
without adding value
Causes:
Poor people/machine
effectiveness
Inconsistent work methods
Unfavorable facility or cell
layout
Poor workplace organization
and housekeeping
20

Waste from product defects


All the time and cost

incurred due to getting


something wrong
Causes:
Weak process control
Poor product & process design
Deficient planned maintenance
Inadequate
education/training/work
instructions
Misunderstood Customer
needs.

21

Lean Principles - Being Fast, Flexible, Economic


5 principles of Lean

Value - specify what creates value from the customers perspective.


The value stream identify all the steps along the process chain.
Flow - make the value process flow.
Pull - make only what is needed by the customer (short term response to
the customers rate of demand).
Perfection - strive for perfection by continually attempting to produce
exactly what the customer wants.

11/10/15

22

Some of the commonly used tools / techniques,


methods in Lean Manufacturing are:
PDCA Cycle
Concentration Diagrams
Paired Comparisons
Impact Diagrams
Forced Field Diagrams
5 Whys
5W+1H
Kaizen
JIT / Kanban System
Quality Circle
Ishikawa Diagram / Fishbone Diagram
5S
TPM
SMED

FIVE S (5S)
5 S is an integrated Japanese concept for proper
housekeeping and they call it as workplace
management. According to them effective work place
management calls for five steps viz., organising, neatness,
cleaning, starndardisation and discipline. Japanese in their
language call these steps as SEIRI, SEITON, SEISO,
SEIKETSU and SHITSUKE.

SEIRI

- Organising or re-organising

SEITON

- Neatness

SEISO

- Cleaning

SEIKETSU - Standardisation
SHITSUKE - Discipline

So the name 5S is
arrived at taking the
first letter S of all
these five activities.

You might also like