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Lean MFG

Lean is a process of eliminating waste with the goal of creating value for stakeholders. The Toyota Production System established concepts like "Jidoka" which stops equipment when problems are detected to prevent defects, and "Just-in-Time" which produces only what is needed for the next process in continuous flow. Five fundamental principles of lean are specifying value, identifying the value stream, making value flow continuously, letting customers pull value, and pursuing perfection through continuous improvement.

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14 views38 pages

Lean MFG

Lean is a process of eliminating waste with the goal of creating value for stakeholders. The Toyota Production System established concepts like "Jidoka" which stops equipment when problems are detected to prevent defects, and "Just-in-Time" which produces only what is needed for the next process in continuous flow. Five fundamental principles of lean are specifying value, identifying the value stream, making value flow continuously, letting customers pull value, and pursuing perfection through continuous improvement.

Uploaded by

Vasant bhoknal
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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Lean is a process of eliminating waste with the goal of creating value for enterprise stakeholders.

Toyota Motor Corporation's vehicle production system is a way of making things that is sometimes referred to as a
"lean manufacturing system," or a "Just-in-Time (JIT) system".
The Toyota Production System (TPS) was established based on two concepts:
"Jidoka" (which can be loosely translated as "automation with a human touch"), as when a problem occurs, the
equipment stops immediately, preventing defective products from being produced; and
"Just-in-Time" concept, in which each process produces only what is needed for the next process in a continuous
flow.
Five Fundamental Principles Of Lean (James Womack & Daniel Jones, Lean Thinking):

I. Specify value: Value is defined by customer in terms of specific products & services
II. Identify the value stream: Map out all end-to-end linked actions, processes and functions necessary for
transforming inputs to outputs to identify and eliminate waste
III. Make value flow continuously: Having eliminated waste, make remaining value-creating steps flow
IV. Let customers pull value: Customerpullcascades all the way back to the lowest level supplier, enabling
just-in-time production
V. Pursue perfection: Pursue continuous process of improvement striving for perfection
25 Essential Tools/ Techniques/ Prininciples/ Methodologies of Lean:
Organize and manage the work area:

· Sort (eliminate that which is not needed)

· Set In Order (organize remaining items)

· Shine (clean and inspect work area)

· Standardize (write standards for above)

· Sustain (regularly apply the standards)


Visual feedback system for the plant floor that indicates production status, alerts when assistance is needed, and
empowers operators to stop the production process.
How does Andon help?
Acts as a real-time communication tool for the plant floor that brings immediate attention to problems as they occur – so
they can be instantly addressed.
3. Bottleneck Analysis
What is Bottleneck Analysis?

Identify which part of the manufacturing process limits the overall throughput and improve the performance of
that
part of the process.

How does Bottleneck Analysis help?


Improves throughput by strengthening the weakest link in the manufacturing process.
4. Continuous Flow
What is Continuous Flow?

Manufacturing where work-in-process smoothly flows through production with minimal (or no)
buffers between
steps of the manufacturing process.
How does Continuous Flow help?
Eliminates many forms of waste (e.g. inventory, waiting time, and transport).
5. Gemba (The Real Place)
What is Gemba?

A philosophy that reminds us to get out of our offices and spend time on the plant floor
– the place where real action occurs.
How does Gemba help?
Promotes a deep and thorough understanding of real-world manufacturing issues – by first-hand observation and
by talking with plant floor employees.
6. Heijunka (Level Scheduling)
What is Heijunka?

A form of production scheduling that purposely manufactures in much smaller batches by sequencing (mixing)
product variants within the same process.
How does Heijunka help?
Reduces lead times (since each product or variant is manufactured more frequently) and inventory
(since batches are smaller).
7. Hoshin Kanri (Policy Management) What is Hoshin Kanri?

Align the goals of the company (Strategy), with the plans of middle management (Tactics) and the work performed on
the plant floor (Action).
How does Hoshin Kanri help?
Ensures that progress towards strategic goals is consistent and thorough – eliminating the waste that comes from poor
communication and inconsistent direction
8. Jidoka (Autonomation) What is Jidoka?

Design equipment to partially automate the manufacturing


process (partial automation is typically much less expensive
than full automation) and to automatically stop when defects
are detected.

How does Jidoka help?


After Jidoka, workers can frequently monitor multiple stations
(reducing labor costs) and many quality issues can be detected
immediately (improving quality).
What is Just-In-Time?

Pull parts through production based on customer demand instead of pushing parts through production based on
projected demand. Relies on many lean tools, such as Continuous Flow, Heijunka, Kanban, Standardized Work and Takt
Time.
How does Just-In-Time help?
Highly effective in reducing inventory levels. Improves cash flow and reduces space requirements.
What is KAIZEN

A strategy where employees work together proactively to achieve regular,


incremental improvements in the manufacturing process.
How does Kaizen help?
Combines the collective talents of a company to create an engine for continually
eliminating waste from manufacturing processes.
What is Kanban?

A method of regulating the flow of goods both within the


factory and with outside suppliers and customers. Based on
automatic replenishment through signal cards that indicate
when more goods are needed.
How does Kanban help?
Eliminates waste from inventory and overproduction. Can
eliminate the need for physical inventories (instead relying on
signal cards to indicate when more goods need to be ordered).
What is KPI

Metrics designed to track and encourage progress towards critical goals of the organization. Strongly promoted KPIs can be
extremely powerful drivers of behavior – so it is important to carefully select KPIs that will drive desired behavior.

How do KPIs help?

The best manufacturing KPIs:


· Are aligned with top-level strategic goals (thus helping to achieve those goals)
· Are effective at exposing and quantifying waste (OEE is a good example)
· Are readily influenced by plant floor employees (so they can drive results)
13. Muda (Waste)

Anything in the manufacturing process that does not add value from
the customer’s perspective.

How does Muda help?

It doesn’t. Muda means ‘waste’. The elimination of muda (waste) is


the primary focus of lean manufacturing.
14. Overall Equipment Effectiveness (OEE)

Framework for measuring productivity loss for a given


manufacturing process. Three categories of loss are tracked:
· Availability (e.g. down time)
· Performance (e.g. slow cycles)
· Quality (e.g. rejects)
How does Overall Equipment Effectiveness help?
Provides a benchmark/baseline and a means to track progress in
eliminating waste from a manufacturing process. 100% OEE means
perfect production (manufacturing only good parts, as fast as
possible, with no down time).
15. PDCA (Plan, Do, Check, Act) What is PDCA?

An iterative methodology for implementing improvements:


· Plan (establish plan and expected results)
· Do (implement plan)
· Check (verify expected results achieved)
· Act (review and assess; do it again)
How does PDCA help?
Applies a scientific approach to making improvements:
· Plan (develop a hypothesis)
· Do (run experiment)
· Check (evaluate results)
· Act (refine your experiment; try again)
16. Poka-Yoke (Error Proofing) What is Poka-Yoke?

Design error detection and prevention into production processes with the goal of achieving zero defects.
How does Poka-Yoke help?
It is difficult (and expensive) to find all defects through inspection, and correcting defects typically gets significantly more
expensive at each stage of production.
17. Root Cause Analysis What is Root Cause Analysis?

A problem solving methodology that focuses on resolving the underlying problem instead of applying quick fixes that
only treat immediate symptoms of the problem. A common approach is to ask why five times – each time moving a step
closer to discovering the true underlying problem.
How does Root Cause Analysis help?
Helps to ensure that a problem is truly eliminated by applying corrective action to the “root cause” of the problem.
Reduce setup (changeover) time to less than 10 minutes. Techniques include:

· Convert setup steps to be external (performed while the process is running)


· Simplify internal setup (e.g. replace bolts with knobs and levers)
· Eliminate non-essential operations
· Create Standardized Work instructions

How does Single-Minute Exchange of Dies help?


Enables manufacturing in smaller lots, reduces inventory, and improves customer
responsiveness.

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