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SUBMITTED BY
NAME: MR SAGAR.G.SEWLANI
PRN NO: 15020448066
Introduction
Lean Manufacturing
Lean manufacturing systems produce what the customer wants,
in the quantity the customer wants, when the customer wants it,
and with minimum resources. Lean efforts typically start in
manufacturing because they free up resources for continuous
improvement in other areas, and create a pull on the rest of the
organization. Applying lean concepts to manufacturing typically
presents the greatest opportunity for cost reduction and quality
improvement; however, many organizations have received huge
benefits from lean concepts in other functions.
Lean Warehousing
Lean warehousing means eliminating non-value added steps and
waste in product storage processes. Typical warehousing functions
are:
Receiving
Put-away/storing
Replenishment
Picking
Packing
Shipping
Warehousing waste can be found throughout the storage
process including:
Defective products which create returns
Overproduction or over shipment of products
Excess inventories which require additional space and
reduce warehousing efficiency
Excess motion and handling
Demand Volatility:
Many companies have also found their Lean strategies thwarted
by the increasing volatile demand environment, and increasingly
complex mix in product portfolio. Supply chain complexity has
many costs, and one of them is making Lean techniques more
difficult to adopt Cleanly.
Disparate Manufacturing Environments:
Lean has been challenged to work well in some complex
manufacturing environments. Ditto with how to translate Lean
principles into process or hybrid manufacturing industries. Most
industries are also struggling with rapidly shrinking product
lifecycles and the need for many new product introductions. The
need to get fast cycle products to market can often trump the
perceived need to operate on Lean principles.
Mediocre Consultants:
A huge consulting industry has developed around Lean, and
spawned a virtual army of boutique Lean consulting firms. Almost
every company uses consultants of some kind at least early in its
Lean journey, and many for longer periods after that. As with any
profession, there are good and not so good Lean consultants, and
no easy process for separating the two. Some know Lean theory
well, but arent able to teach it nearly as well as they can do it
themselves. Many Lean projects have stalled because consultants
couldnt move the project in the right way.
Lack of Staying Power:
All these factors combine to make it challenging for some
companies to get Lean right from the outset. Add to that the
manufacturing cost pressures mentioned above, and if a Lean
initiative actually sends costs going in the wrong direction at the
start, companies frequently cancel the program rather than fixing
what went wrong with a proven methodology .
It helps you visualize more than just the single-process level, i.e.
assembly, welding, etc., in production. You can see the flow.
It helps you see more than waste. Mapping helps you see the
sources of waste in your value stream.
It provides a common language for talking about manufacturing
processes.
It makes decisions about the flow apparent, so you can discuss
them. Otherwise, many details and decisions on your shop floor
just happen by default.
It ties together lean concepts and techniques, which help you,
avoid cherry picking.
It forms the basis of an implementation plan. By helping you
design how the whole door-to-door flow should operate a
missing piece in so many lean efforts value stream maps
become a blueprint for lean implementation. Imagine trying to
build a house without a blueprint!
It shows the linkage between the information flow and the
material flow. No other tool does this.
NEXT FUTURE
STATE
FUTURE STATE
ORIGINAL
STATE
CURRENT
Data Box
The Data Box stores process information
Cycle Time (C/T). Rate at which a part or product is completed
by a process.
Changeover Time (C/O). Amount of time to switch from one
product type to another.
Uptime. Measure of machine use (100% = Always running).
Mapping Methodology
Investigation Etiquette
10.6 Sec/Board
85 Boards
Cycle Time = Minimum # of People
Takt Time
GOAL: Produce to
Demand