ashish sontakke_lean_mfg

PRESENTATION ON LEAN

MANUFACTURING

By Ashish R. Sontakke

M.Tech.Cad-Cam Roll No.-16

VNIT

What is LEAN MANUFACTURING??

“The production of goods using less of everything by reducing ‘waste’ and increasing value

added activity”

ORIGIN

Lean Manufacturing is sometimes called the Toyota Production System (TPS) because Toyota Motor Company’s Eiji Toyoda and Taiichui Ohno are given credit for its approach and innovations

“Key” Lean Manufacturing Techniques

1. Elimination of waste2. 5s3. JIT/Pull production system4. Cellular Manufacturing5. KANBAN

What is Waste?

• Waste is anything that happens to a product that does not add value from the customer’s perspective

• Products being stored, inspected or delayed, products waiting in queues, and defective products do not add value

The 8 wastes

Introduction to ‘TIM WOODS’ T – Transport

I – InventoryM – MovementW – WaitingO – Over-processingO – Over-productionD - DefectsS - Skill

5s

1.Seiri -Sorting2.Seiton-Stabilizing or Straightening Out3.Seiso-Sweeping or Shining4.Seiketsu-Standardizing5.Shitsuke-Sustaining the Practice

5S Examples

Before After

JIT/Pull system

• JIT literally means Just In Time.• It aims to produce only what is needed, when

it is needed. • Production is pulled by the downstream

workstation so that each workstation should only produce what is requested by the next workstation.

• One-piece flow is key implementation which means that parts are moved through operations from step-to-step with no WIP in between either one piece at a time or a small batch at a time.

Gravity Conveyor for one piece flow between two machines

Cellular manufacturing

1.In Functional Manufacturing similar machines are placed close together (e.g. lathes, millers, drills etc.).

2.In Cellular Manufacturing systems machines are grouped together according to the families of parts produced.

3.The major advantage is that material flow is significantly improved, which reduces the distance travelled by materials.

Cellular manufacturing

Example of Cell

KANBAN

A system of continuous supply of components and parts such that workers have what they need, where they need, when they need it

KANBAN is the process through JIT is achieved

Assembly line (KANBAN)

Key Implications of lean manufacturing

Traditional LeanOrientation Supply driven Customer driven

Planning Orders are pushed though factory based on production plan/forecast

Orders are pulled through factory based on customer/downstream demand

Batch size Large small

Quality inspection

Checking of samples by QC inspectors

In-line inspection by workers

Inventory Buffer of work-in-progress

Little or no work-in-progress

Advantages

• Increased overall productivity• Reduced amount of floor space required• Reduced manufacturing lead time• Improved flexibility to react to changes• Improved quality• Less inventory• Increases working standards• Increases worker talents

Disadvantages

• Success of lean requires the full commitment and involvement of all employees.

• Long term commitment required (i.e. workers should give full support to apply lean)

THANK YOU