Presentation On

Lean Manufacturing
By: Nitin Mukesh Mahawar Sheetal Kumar Jain JNIT, Final Year Mechanical Branch

ABSTRACT
Before 1950, companies mainly focused on the mass production but after that number of companies started. Due to this, the competition in the market increases continuously. So to prevent from this problem company focused on the lean manufacturing. Lean manufacturing is a management philosophy focusing on reduction of the seven wastes to improve overall customer value. By eliminating waste (muda), quality is improved, production time and costs are reduced. So there are various methods and tools are used to reduce the wastes and improved the efficiency of production.

Presentation Outline
History Definition Lean and Just in time Wastes Six tools of lean Basic Elements of Lean Production Benefits of Lean Production Implementing Lean Production Problems Case study

History
Lean Manufacturing is sometimes called the Toyota Production System (TPS) because Toyota Motor Companys Shigeo Shingo and Taiichui Ohno are given credit for its approach and innovations in the 1950.

Definition
Lean Manufacturing A way to eliminate waste and improve efficiency in a manufacturing environment Lean focuses on flow, the value stream and eliminating muda, the Japanese word for waste Lean manufacturing is the production of goods using less of everything compared to traditional mass production: less waste, human effort, manufacturing space, investment in tools, inventory, and engineering time to develop a new product.

Lean and Just-in-Time

Lean was generated from the Just-in-time (JIT) philosophy of continuous and forced problem solving

Just-in-time is supplying customers with exactly what they want when they want it with JIT, supplies and components are pulled through a system to arrive where they are needed when they are needed

What is Waste?
Waste is anything that happens to a product that does not add value from the customers perspective
Products being stored, inspected or delayed, products waiting in queues, and defective products do not add value

Mainly Seven types of the waste:

1. Overproduction
2. Waiting 3. Transporting 4. Unnecessary Processing 5. Unnecessary Inventory 6. Unnecessary/excess Motion 7. Defects

Six Tools for Lean Maintenance:

Visual Controls 5S Seven Wastes Single Minute Exchange of Dies Poka-yoke Total Productive Maintenance

10

5S
Strategy for creating a well organized, smoothly flowing manufacturing process

11

Basic Elements of Lean Production:

1. Flexible resources

2.
3. 4. 5. 6.

Cellular layouts
Pull production system Kanban production control Small lot production Quick setups

7.
8.

Uniform production levels

Total productive maintenance

9.

Supplier networks

Before

1. Cellular Layouts: comprised of dissimilar machines brought together to manufacture a family of parts

After

2. Flexible Resources: Multifunctional Workers Cycle time Reduced

3. Pull Production System: Material is pulled through the system when needed Prevent over and underproduction 4. Kanbans Production Control: Card which indicates standard quantity of production Maintain discipline of pull production

5. Small Lot Production: Require less space and capital investment Make quality problems easier to detect Make processes more dependent on each other

6. Quick Setups: Based on Single Minute Exchanges of Dies ( SMED )

7. Uniform Production Levels:

8. Total Productive Maintenance (TPM):

Breakdown maintenance Repairs to make failed machine operational Preventive maintenance System of periodic inspection and maintenance to keep machines operating TPM combines preventive maintenance and total quality concepts 9. Supplier Networks:

Mixed loads and frequent deliveries Precise delivery schedules Standardized, sequenced delivery Synchronized production

Benefits of Lean Production:

Reduced inventory Improved quality Lower costs Reduced space requirements Shorter lead time Increased productivity

Benefits of Lean Production (cont.)

Greater flexibility Better relations with suppliers Simplified scheduling and control activities Increased capacity Better use of human resources More product variety

How People Benefit from Lean:

Element
Communication

Traditional
Slow & Uncertain

Lean
Fast & Positive

Improvement
Quality & Coordination Effective Teams

Teamwork

Inhibited

Enhanced

Motivation

Negative, Extrinsic

Positive, Intrinsic

Strong Motivation

Skill Range

Narrow

Broad

Job Enrichment

Supervision

Difficult and Fragmented

Easy & Localized

Fewer Supervisors

20

Implementing Lean Production:

Use lean production to finely tune an
operating system Somewhat different in USA than Japan Lean production is still evolving Lean production isnt for everyone

Problems:
Difficulty involved with changing processes to implement lean principals Long term commitment required Very risky process - expect supply chain issues while changing over to lean