“LEAN MANUFACTUING-CONCEPT, LIMITATION, APPLICATIONS: AN
OVERVIEW”
Submitted By
Ms. PUNAM NIVRUTTI PATIL
DPGD/OC13/1243
SPECIALIZATION: OPERATIONS
WELINGKAR INSTITUTE OF MANAGEMENT DEVELOPMENT & RESEACH
AUGUST 2015
INTRODUCTION
• Lean manufacturing- A way to eliminate waste & improve efficiency in manufacturing environment.
• Lean was generated from just in time(JIT) Philosophy of continuous & forced problem solving.
• Lean is the fundamental way that many of the world’s best companies do business.
• It is the production of goods using less everything compared to traditional mass production.
FORMS OF WASTE
• Muda- Any form of waste in process
• Muri- Unreasonable burden on people or machines
• Mura- Waste created through unevenness
LEAN MANUFACTURING PROCESS
Identify waste Analyze the waste & find
the root cause
Solve the root cause & repeat
the cycle
TOOLS
• 5 S
• Andon
• Bottleneck Analysis
• Continuous flow
• Gemba
• Heijunka
• Hoshin kanri
• Jidoka
• Just In Time
• kaizen
• Kanban
• Key performance indicator
• Overall equipment effectiveness
• PDCA
• Poka Yoke
• Root cause analysis
• SMED
• Takt time
• Total productive maintenance
• Value stream mapping
• Visual factory
Some of important tools
5 S
• Clearing (Seiri)
• 2. Organizing (Seiton)
• 3. Cleaning ( Seiso)
• 4. Standardization (Seiketsu)
• 5. Discipline & Training (Shitsuke)
Just In Time
• The ideal just in time facility would carry zero finished goods and build them only when they are ordered
kaizen
• Kaizen simply means "change for better“
• The Toyota Production System is known for kaizen
KANBAN
• The basic concept of a kanban is a hand
sized card that moves with the product or
material.
• There are two basic classifications of
kanbans; generic and brand.
• Within the two classifications there are
two main types of kanbans; production
kanbans and move kanbans
Total Productive
Maintenance
TPM (Total Productive Maintenance) is a
holistic approach to equipment
maintenance that strives to achieve
perfect production:
No Breakdowns
No Small Stops or Slow Running
No Defects
In addition it values a safe working
environment:
No Accidents
KEY IMPLICATIONS OF LEAN MANUFACURING
Traditional Batch Manufacturing Lean Manufacturing
Orientation Supply driven Customer driven
Planning Orders as pushed through factory based on production plan / forecast
Orders are pulled through factory based on customer / downstream demand
Inventory Buffer of work in progress between each production stage
Little or no wok in progress between each production stage
Handoff of work in process Material after each stage accumulate into work in progress stage areas before being retrieved by next production stage
Material handed of directly from one production stage to next
Production cycle time Longer than actual time Shorter
LIMITATIONS
• Supply Problems • High cost of implementation • Lack of acceptance by employees • Customer dissatisfaction problems • New inefficiencies • Problems in Just In Time (JIT) • Worker frustration • Over focus on waste • Over focus on present • Lack of standard methodology
APPLICATIONS
• In process industries
• In financial service sector
• In emergency department
• In construction industries
• In pharmaceutical industries
• In public
Toyota Production System
TPS has three desired outcomes:
• To provide the customer with the highest quality vehicles, at lowest possible cost, in a timely manner with the shortest possible lead times.
• To provide members with work satisfaction, job security and fair treatment.
• It gives the company flexibility to respond to the market, achieve profit through cost reduction activities and long-term prosperity.
CONCLUSION
Lean manufacturing is:
“A systematic approach to identifying and eliminating waste (non-value added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection”.
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