Chapter 1

Overview of Lean Manufacturing

1.1
1.2
1.3
1.4
1.5

Understanding Lean Thinking

The Lean Manufacturing Model
Understanding Wastes
Understanding VA/NVA
Understanding 3M

LEAN
Manufacturing
Code: JQB 31203
Credit Value: 3(2,1,0)
Hj.Mazlan Awang
Hp: 017-7711366
Email: mazlana@unikl.edu.my
Room: Admin 1301

QUALITY ENGINEERING
PHILOSOPHY AND PRINCIPLE

LEAN SIX SIGMA

AND
INDUSTRIAL
ENGINEERING

QUALITY SYSTEM
AND
IMPROVEMENT
METHOD

ENGINEERING DRAWING
AND DESIGN

INSPECTION TECHNOLOGY
AND METROLOGY (ITM)

DO RIGHT
DO THINGS RIGHT
@ EFFICIENCY

THINGS @
EFFECTIVENESS

MATERIAL,
MANUFACTURING AND MAINTENANCE (3M)

Communication
Skills

Technical
Foundation

Entrepreneur
Techno

ICT

Social
Science

Development of LEAN Mfg

1908/1927..16M

Lean Manufacturing/ JQB31203 / Mazlan2016

1990

1996

1990s
Transition from
Manufacturing to
Service Industry
(in the US)

UniKL MITEC / Sept 2013

2000s
2010s

Lean Production Model

Goal of Customer focus:
Highest quality, lowest cost, shortest lead time by continually eliminating muda

Pace of production is
synchronized with the
rate of sales

Strategic planning in-line

with company goal

Automation with
human mind

Production leveling

Lean Manufacturing/ JQB30503 / Mazlan2011

What is Lean ??

FINANCE

lean management
lean manufacturing
lean healthcare
pengurusan lean

HEALTHCARE

Introduction to Lean Concepts

Lean includes principles, methods and
tools used to improve process efficiency
by removing wasteful steps

Introduction to Lean Concepts

Lean includes principles, methods and
tools used to improve process efficiency
by removing wasteful steps

WASTE ELEMINATION
Firman Allah yang bermaksud:
Sesungguhnya orang yang membazir itu adalah saudara-saudara
syaitan dan syaitan itu adalah sangat ingkar kepada Tuhannya
(Surah al-Isra', ayat 27).

"Demi Masa! Sesungguhnya manusia itu di dalam kerugian.

Kecuali mereka yang beriman, beramal soleh dan berpesan-pesan
dengan kebenaran serta berpesan-pesan dengan kesabaran.
(Al 'Asr 103: 1-3)

7 Wastes of Manufacturing

(Defect)

8 Knowledge Disconnection
Lean Manufacturing/ JQB31202 / Mazlan2011

What is Lean Organization

Lean Manufacturing/ JQB31202 / Mazlan2011

Typically, non-value
added activities
accounts for 95% of
the total lead time

Lean Resource Center Universiti Kuala Lumpur Malaysian Institute of Industrial Technology

Value OR No Value ???

Counting
Sorting
Moving
Inspecting
Waiting
Handling
Rework

Sign confirmation
Delays
Regulatory work
Reporting
Risk
Safety

Understanding

Muda, Mura & Muri

Discuss all possibilities to move 6000kg load with
a forklift having a max. capacity of 2850kg ?

Waste on Complexity
@1000kg

Lean Manufacturing/ JQB31202 / Mazlan2011

Lean Concept
To eleminate 3M
Muda, Mura & Muri
Muda- Any activities for which
customer not wiling to pay

Muda Wasteful Activity

Mura Waste of Inconsistency
Muri- Waste on Complexity

Order fluctuation/
Uneveness

Unreasonableness/
Unrealistic
Ex:Type writing speed
[25-35-40:70:120]

1000kg

Discuss all possibilities to move

6000kg load with a forklift having
a max. capacity of 2850kg ?
Lean Manufacturing/ JQB31202 / Mazlan2011

Journey towards

Lean
Thinking....