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Lean

Lean manufacturing aims to eliminate waste in the value stream to reduce costs and increase competitiveness. It identifies seven types of waste including defects, overproduction, and excess inventory. The principles of lean include creating continuous flow, using pull systems, reducing batch sizes, and eliminating waste. Implementing lean offers benefits like reduced scrap, improved safety, and increased sales. It involves analyzing current processes, identifying waste, and implementing tools like just-in-time production and value stream mapping to streamline material and information flow.

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lalit2585
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63 views

Lean

Lean manufacturing aims to eliminate waste in the value stream to reduce costs and increase competitiveness. It identifies seven types of waste including defects, overproduction, and excess inventory. The principles of lean include creating continuous flow, using pull systems, reducing batch sizes, and eliminating waste. Implementing lean offers benefits like reduced scrap, improved safety, and increased sales. It involves analyzing current processes, identifying waste, and implementing tools like just-in-time production and value stream mapping to streamline material and information flow.

Uploaded by

lalit2585
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
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Lean Manufacturing

Lean Manufacturing
 Lean manufacturing is to work in every facet of 
the value stream by eliminating waste in order to 
reduce cost, generate capital, bring in more sales, 
& remain competitive in a growing global market
 The value stream is defined as “the specific 
activities within a supply chain required to design, 
order and provide a specific product or value”
 Waste sources are all related to each other and 
getting rid of one source of waste can lead to 
Types of Waste (Muda)
 Defects
 Overproduction
 Waiting
 Inventory
 Excess motion
 Transportation
 Inappropriate processing
Principles of Lean
 To create continuous flow  
 To use pull­systems to manage the work flow 
 To reduce batch sizes and inventories 
 To eliminate waste 
 To cross­train workers in order to deal with 
inherent variability 
 Selective use of automation 
 To instill a Continuous Improvement competence 
Why Lean ?
 Less scrap
 Safety of operations
 Reduced work in progress 
 Decreased lead times 
 Increased floor space 
 Workforce development 
 Increased sales
Traditional Lean
 Complex  Simple and Visual
 Forecast Driven  Demand Driven
 Excessive Inventory  Inventory as Needed
 Speed Up Value­  Reduce Non­Value­
Added Work Added
 Large Batch   Small Lot Size
Production  Minimal Lead Time
 Long Lead Time  Quality Built­in
Implementation of Lean
Three stages of implementation are:

 Data collection stage
 Data analysis and development of solution Stage 
 Implementation Stage
Process of Implementation
Value stream mapping
 Follow a “product” or “service” from beginning to 
end
 Draw a visual representation of every process in 
the material & information flow
Tools to move closer..
 Cellular Manufacturing
 Continuous Improvement – Kaizen, 5S
 Just­In­Time, Kanban system
 Electronic Data Interchange
 Value Stream Mapping
 Total Productive Maintenance
 Six sigma
Create/Implement the Plan
 Create the training plan
 Document expectations of employees
 Establish criteria for lean project selections
 Define the structure for task teams
 Create a team and get a project completed
 Assess results and reward the contributing 
employees
 Reap the benefits
Steps to achieve Lean
Understand your value stream
 Develop “eyes for waste” & remove it
 Create process stability & flow
 Standardize work & use visual controls
 Change your culture by developing your people 
& partners
 Become a learning organization through 
relentless reflection & continuous improvement
Cycle Time Reduction
 Map all processes in each department
 Calculate time required by each process & no of 
workers involved in each
 Analyze variations during product manufacturing
 Check for the rejected product quantity
Flow Analysis
 Order Processing (Information sharing)
 P.P.C. Dept. Operations
 Release of Production Schedules
 Production Target attainment per shift
 Info & material flow
 Procurement lead time
 Q.A. Clearance time
 Transportation facilities (inside & outside plant)
Cont'd...
 Locate points requiring maximum & minimum 
time in production
 Synchronization with other depts
 Storage points near production line
Thank You ...!!

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