An Assignment on Latest Developments in Lean Manufacturing

Submitted to: Prof. A B Raju Submitted by: Dipesh Bhimani Subject: Total Quality Management Batch:FC 4 (1)

TQM
Que: Latest development in Lean Manufacturing.

Concept & History of Lean Manufacturing:

Lean manufacturing is a

production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination. Working from the perspective of the customer who consumes a product or service, "value" is defined as any action or process that a customer would be willing to pay for. Essentially, lean is centered on preserving value with less work. Lean manufacturing is a management philosophy derived mostly from the Toyota Production System (TPS) (hence the term Toyotism is also prevalent) and identified as "Lean" only in the 1990s.[1][2] TPS is renowned for its focus on reduction of the original Toyota seven wastes to improve overall customer value, but there are varying perspectives on how this is best achieved. The steady growth of Toyota, from a small company to the world's largest automaker,[3] has focused attention on how it has achieved this. Lean manufacturing is a variation on the theme of efficiency based on optimizing flow; it is a present-day instance of the recurring theme in human history toward increasing efficiency,

decreasing waste, and using empirical methods to decide what matters, rather than uncritically accepting pre-existing ideas. As such, it is a chapter in the larger narrative that also includes such ideas as the folk wisdom of thrift, time and motion study, Taylorism, the Efficiency Movement, and Fordism. Lean Manufacturing is a unified, comprehensive set of philosophies, rules, guidelines, tools, and techniques for improving and optimizing discrete processes. While Lean was born in large volume, repetitive manufacturing for the automotive industry sector, Lean principles and benefits apply to all processes (health care, service, high tech, sales & marketing, fast food, etc.). For this reason, some call it "Lean Thinking", rather than the more restrictive title of "Lean Manufacturing". All employees in a lean manufacturing company are expected to examine their jobs for ways to eliminate waste and to continually improve the processes. This concept of continuous improvement is called kaizen. In addition, company management is expected to have great respect for the employees and to continuously look for new ways to make their jobs more satisfying and empowering.

Understanding Lean Technology

Lean is a business philosophy which has been around in many forms since the 1900s. Lean technology is not about purchasing more technology or software systems; rather, it is about seeking the most efficient software system that provides businesses with the information they need. Businesses must have information to identify and eradicate waste throughout their organization. Software such as Computerized Maintenance Management Systems (CMMS) or Enterprise Asset Management (EAM) is an integral part of the lean management information gathering and maintenance process.

The characteristics of lean processes are: Single-piece production order characteristics -In-Time materials/pull scheduling

-skilled employees

-pass yields with major reductions in defects Lean Manufacturing incorporates the use of Heijunka, level sequential flow, Takt time, the heartbeat or pace of the production system, continuous flow manufacturing, cellular manufacturing, and pull production scheduling techniques such as Kanban.

Latest Tools and Techniques of Lean Manufacturing:

Value Mapping SMED (Single Minute Exchange of Dies) 1-Piece Flow KanBan (Inventory Control via Card System) Poka Yoke (Mistake Proofing) & Jidoka 5S (Separate, Simplify, Standardize, Sustain) Total Productive Maintenance Visual Management - see example of visual work instruction Line Optimization Synchronous Manufacturing

Developments in Lean Manufacturing:

Understanding How Technology Supports Lean Businesses seeking to implement a lean technology solution to their problems must be able to gather and analyze information that supports lean activities. Lean solutions will be available with the appropriate software to track progress and identify further areas of improvement. Software must integrate between departments to police past data and enforce compliance with lean principles, making sure there is no backsliding. Lean performance measurements must be included in any software program so that management can verify that lean performance goals are being met. Lean maintenance is part of the lean technology process. Software that enumerates the many business activities and

communicates these activities to various individuals is essential to the lean technology process.

Software and Lean Technology: Efficiency Lean technology is about getting more with less. Utilizing the right computer software for your business allows staff at every point in the value stream to perform at optimal efficiency. Care should be taken to understand the needs of the organization and the data that should be gathered. Appropriate software will support the lean technology goals of the business.

Lean Technology and Tracking Costs Utilizing appropriately-designed software will allow businesses to track costs, such as tools, repairs and maintenance, with an eye to minimizing costs at every point in the production process. Adequate tracking of a variety of data is one part of the lean management process. Lean technology tracking, combined with engaged and informed employees, helps management achieve lean goals.

Steps to achieve lean systems

The following steps should be implemented to create the ideal lean manufacturing system: 1. Design a simple manufacturing system 2. Recognize that there is always room for improvement 3. Continuously improve the lean manufacturing system design

References: http://www.ehow.com/about_6718585_lean-technology-business.html