Lean Manufacturing - Group Presentation

8/22/2019 Lean Manufacturing - Group Presentation

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Lean ManufacturingAn Overview

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Roll # 2 Arun Kumar

Roll # 8 Kamiya Gulati

Roll # 20 Shreerajavel Rengaraj

Roll # 14 Mayank Mathur

POIM PresentationsGuide : Prof. T.P.S Bawa

X-MBA 24ITM Vashi


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The Flow o Introduction

o Value discussion

o What is Lean Manufacturing

o History of Lean

o Principles of Lean

o Terms used in Lean Manufacturing

o Tools of Lean Manufacturing

o Benefits of Lean Manufacturing

o Conclusion

o Acknowledgement & References

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Who wants what...

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CustomerLow Cost

High Quality

Availability

Company

Profit

Repeat Business

Growth

Value !!

Cash !!


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Value ...

The Manufacturing or business process is a Value Stream i.e. mailmandelivering mail is a part a value stream.

Any process that delivers value to the customer is a value stream

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The thought process of lean was thoroughly described in the

book The Machine That Changed the World(1990) by James P.Womack, Daniel Roos, and Daniel T. Jones.

In a subsequent volume, Lean Thinking(1996), James P.

Womack and Daniel T. Jones distilled these lean principles even

further to five:

1. Specify the value desired by the customer2. Identify the value stream for each product providing that

value and challenge all of the wasted steps (generally nine

out of ten) currently necessary to provide it

3. Make the product flow continuously through the remaining

value-added steps4. Introduce pull between all steps where continuous flow is

possible

5. Manage toward perfection so that the number of steps and

the amount of time and information needed to serve the

customer continually falls 8
http://www.lean.org/Bookstore/ProductDetails.cfm?SelectedProductID=160http://www.lean.org/Bookstore/ProductDetails.cfm?SelectedProductID=88http://www.lean.org/Bookstore/ProductDetails.cfm?SelectedProductID=88http://www.lean.org/Bookstore/ProductDetails.cfm?SelectedProductID=160


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Lean ManufacturingA manufacturing philosophy which shortens the time line between

the customer order and the product shipment by eliminating waste.

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Business as Usual

Lean Manufacturing

Time (Shorter)

Customer

OrderProduct

Shipment

Waste

Customer

Order

Waste

Time

Product

Shipment


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Lean Manufacturing

Deliberately simple way of thinking about customer value and how

operations can build that value in the most efficient way possible

o Asks to think of manufacturing operations as a value stream that

flows products to customers

o Some of activities add value , others just add waste.

o Value is anything customer will pay foro Waste is anything that adds costs customer would not pay for

o This could be over production of finished goods / working process

excess transport and handle of scrap & rework or wasted time while

people and goods wait for things to happen

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As one works to drive out all waste and flow product more quickly

through the value stream the operation becomes less costly and more

responsive to customer demand


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Lean Manufacturing

Business philosophies invoked by lean manufacturing

include

o Kaizen

o Just-in-Time (JIT) Manufacturing

o Total Quality Management (TQM)

o Total Productive Maintenance (TPM)

o Cellular Manufacturing

The roots of lean manufacturing can be traced to Japan,

or more specifically , Toyota.

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http://www.siliconfareast.com/jit.htmhttp://www.siliconfareast.com/tqm.htmhttp://www.siliconfareast.com/tpm.htmhttp://www.siliconfareast.com/tpm.htmhttp://www.siliconfareast.com/tqm.htmhttp://www.siliconfareast.com/jit.htm


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History of Manufacturing Management

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Principles of Lean Manufacturing

Lean manufacturing operates on following principles:

o Muda' or waste, is bad

o Manufacturing processes must be closely tied to the market's

requirements&

o Company should be seen as a continuous and uniform whole that includes

its customers & suppliers, a concept known as Value Stream'

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Lean manufacturing is not merely a tool - it is a way of life that all

members of an organization must appreciate, and practice.


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What makes a manufacturing system lean ?

Muda Waste Mura Inconsistency

Muri Unreasonableness

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The 3 Ms of lean


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What makes a manufacturing system Lean?

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Waste

Anything that adds Cost to the product

without adding Value

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7 Types ofMuda

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Basic Elements of Lean Manufacturing


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Basic Elements of Lean Manufacturing

o Just-in-time, higher efficiency manufacturing through theprinciple of 'continuous product flow' (Single Piece Workflow )

o Continuous improvement of processes along the entire value

chain, primarily in terms of quality and cost

o Setting up of multi-functional and multi-skilled teams at all

levels to achieve its goals

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Lean manufacturing is, the 21st centurys upgraded version

of the 20th century's Mass-Production philosophy.


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An Element Continuous Product Flow

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Continuous Product Flow redesign of the productionfloor , product manufactured progressively from one

workstation to another with minimal waiting time &

handling operations between stations.

o Dedication of an entire process line to a group of

similar products, or a group of products that undergo

similar processing.

o Equipment and worktables are arranged in a

'streamlined' lay-out that keeps production continuous

and efficient.

o Also known as CellularManufacturing'.

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Animation

Movie time
http://localhost/var/www/apps/conversion/tmp/scratch_5/Lean%20Management%20-%20Get%20Lean%20in%2090%20Seconds.flvhttp://localhost/var/www/apps/conversion/tmp/scratch_5/Lean%20Management%20-%20Get%20Lean%20in%2090%20Seconds.flvhttp://localhost/var/www/apps/conversion/tmp/scratch_5/Lean%20Management%20-%20Get%20Lean%20in%2090%20Seconds.flvhttp://localhost/var/www/apps/conversion/tmp/scratch_5/Lean%20Management%20-%20Get%20Lean%20in%2090%20Seconds.flvhttp://localhost/var/www/apps/conversion/tmp/scratch_5/Lean%20Management%20-%20Get%20Lean%20in%2090%20Seconds.flv


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Lean Manufacturing tools

o Kaizen

o Value Stream Mapping - Material & information flow mapping

o Standardized Work

o Pull System

o Andon - Status display board

o Kanban - Signal card , pull card

o Leveled Production Schedule

o Visual Management

o Workplace Organization - 5 S

o Jidoka - Stop the line, fix the problem

o Fixed Position Stop System

o Pokayoke - Failsafe, Error proofing devices

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Kaizen or the Japanese concept of 'continuous improvement

Lean manufacturing promotes teamwork among multi-skilled,multifunctional individuals at all levels to effect the continuous

achievement of process improvements toward zero non-moving

inventories, zero downtimes, zero paper, zero defects and zero delays all

throughout the organization.

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http://www.siliconfareast.com/kaizen.htmhttp://www.siliconfareast.com/kaizen.htm


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o To standardize a method is to choose out of the manymethods the best one, and use it. Standardizationmeans nothing unless it means standardizing upward.

o Todays standardization, instead of being a barricade

against improvement, is the necessary foundation onwhich tomorrows improvement will be based.

o If you think of standardization as the best that youknow today, but which is to be improved tomorrow -you get somewhere. But if you think of standards as

confining, then progress stops.Henry Ford , 1926

Today & Tomorrow

Henry Ford - Standards

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Th I t f St d di d W k


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The Importance of Standardized Work

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Without it, allimprovement

efforts using

Kaizen to

eliminate waste

(muda) are not

sustainable.

One will go back

to the original

position beforeKaizen.


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5S Programs -

Seiri (sort, necessary items)

Seiton (set-in-order, efficient placement)

Seison (sweep, cleanliness)

Seiketsu (standardize, cont. improvement)

Shitsuke (sustain, discipline)

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Visual Factory

Visual Factory


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Visual Factory

Ability to understand the status of a production area in 5 minutes or less bysimple observation without use of computers or speaking to anyone.

5-S

1S Sift and Sort

(Organize)

2S Stabilize

(Orderliness)

3S Shine

(Cleanliness)

4S Standardize

(Adherence)

5S Sustain

(Self-discipline)

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Benefits of Lean Manufacturingo Waste reduction - therefore production cost reduction

o Shorter manufacturing cycle times

o Lower manpower requirements

o Minimal inventories

o Higher equipment utilization and manufacturing capacity

o Improved cash flow

o Higher product quality and reliability

o Better customer service

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Profits of the company - Increase because of these benefits.

C l i


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The entire process - the value stream - from the most basic

supplier to the final end customer must be optimized.

Optimized means synchronizing, tightening and integratingthe sequence of steps to maximize the efforts creating value

for that end customer & eliminating anything and everything

that is not contributing to customer value.

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Conclusion


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What Next...

o World Class Manufacturing-21st Century State of the Art

for Manufacturing Companies

o Agile manufacturing

o Whats Next After Lean Manufacturing?

o http://sloanreview.mit.edu/article/innovation-whats-next-

after-lean-manufacturing/

o 6 Sigma

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http://sloanreview.mit.edu/article/innovation-whats-next-after-lean-manufacturing/http://sloanreview.mit.edu/article/innovation-whats-next-after-lean-manufacturing/http://sloanreview.mit.edu/article/innovation-whats-next-after-lean-manufacturing/http://sloanreview.mit.edu/article/innovation-whats-next-after-lean-manufacturing/http://sloanreview.mit.edu/article/innovation-whats-next-after-lean-manufacturing/http://sloanreview.mit.edu/article/innovation-whats-next-after-lean-manufacturing/http://sloanreview.mit.edu/article/innovation-whats-next-after-lean-manufacturing/http://sloanreview.mit.edu/article/innovation-whats-next-after-lean-manufacturing/http://sloanreview.mit.edu/article/innovation-whats-next-after-lean-manufacturing/http://sloanreview.mit.edu/article/innovation-whats-next-after-lean-manufacturing/http://sloanreview.mit.edu/article/innovation-whats-next-after-lean-manufacturing/http://sloanreview.mit.edu/article/innovation-whats-next-after-lean-manufacturing/http://sloanreview.mit.edu/article/innovation-whats-next-after-lean-manufacturing/


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Acknowledgement & Referenceso All resources taken from the www are gratefully acknowledged .

o http://www.toyota-

global.com/company/vision_philosophy/toyota_production_system/origin_of_the

_toyota_production_system.html

o http://www.lean.org/WelcomeLetter.cfm

o http://www.shmula.com/lean-history-and-timeline-toyota-production-

system/5993/o http://en.wikipedia.org/wiki/Taiichi_Ohno

o http://en.wikipedia.org/wiki/The_Machine_That_Changed_the_World_(book)

o http://en.wikipedia.org/wiki/James_P._Womack

o http://en.wikipedia.org/wiki/Sakichi_Toyoda

o http://en.wikipedia.org/wiki/Henry_ford

o Quiz on Toyota site : http://www.toyota-

global.com/company/vision_philosophy/toyota_production_system/quiz_on_the_

toyota_production_system.html

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http://www.toyota-global.com/company/vision_philosophy/toyota_production_system/origin_of_the_toyota_production_system.htmlhttp://www.toyota-global.com/company/vision_philosophy/toyota_production_system/origin_of_the_toyota_production_system.htmlhttp://www.toyota-global.com/company/vision_philosophy/toyota_production_system/origin_of_the_toyota_production_system.htmlhttp://www.lean.org/WelcomeLetter.cfmhttp://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://en.wikipedia.org/wiki/Taiichi_Ohnohttp://en.wikipedia.org/wiki/The_Machine_That_Changed_the_World_(book)http://en.wikipedia.org/wiki/James_P._Womackhttp://en.wikipedia.org/wiki/Sakichi_Toyodahttp://en.wikipedia.org/wiki/Henry_fordhttp://www.toyota-global.com/company/vision_philosophy/toyota_production_system/quiz_on_the_toyota_production_system.htmlhttp://www.toyota-global.com/company/vision_philosophy/toyota_production_system/quiz_on_the_toyota_production_system.htmlhttp://www.toyota-global.com/company/vision_philosophy/toyota_production_system/quiz_on_the_toyota_production_system.htmlhttp://www.toyota-global.com/company/vision_philosophy/toyota_production_system/quiz_on_the_toyota_production_system.htmlhttp://www.toyota-global.com/company/vision_philosophy/toyota_production_system/quiz_on_the_toyota_production_system.htmlhttp://www.toyota-global.com/company/vision_philosophy/toyota_production_system/quiz_on_the_toyota_production_system.htmlhttp://www.toyota-global.com/company/vision_philosophy/toyota_production_system/quiz_on_the_toyota_production_system.htmlhttp://en.wikipedia.org/wiki/Henry_fordhttp://en.wikipedia.org/wiki/Sakichi_Toyodahttp://en.wikipedia.org/wiki/James_P._Womackhttp://en.wikipedia.org/wiki/The_Machine_That_Changed_the_World_(book)http://en.wikipedia.org/wiki/Taiichi_Ohnohttp://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://www.shmula.com/lean-history-and-timeline-toyota-production-system/5993/http://www.lean.org/WelcomeLetter.cfmhttp://www.toyota-global.com/company/vision_philosophy/toyota_production_system/origin_of_the_toyota_production_system.htmlhttp://www.toyota-global.com/company/vision_philosophy/toyota_production_system/origin_of_the_toyota_production_system.htmlhttp://www.toyota-global.com/company/vision_philosophy/toyota_production_system/origin_of_the_toyota_production_system.htmlhttp://www.toyota-global.com/company/vision_philosophy/toyota_production_system/origin_of_the_toyota_production_system.html


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Questions ?

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Thank You

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Documents

Lean Manufacturing - Group Presentation