LEAN MANUFACTURING

Presented By:
Gaurav Kumar
Manish Gupta
Pavan Ghargi
 Lean Manufacturing Is:

• It is focusing on the ELIMINATION of

WASTE (non-value-added activities)
through CONTINUOUS
IMPROVEMENT!
Lean
Manufacturing

3 Pronged Approach
 What makes a
manufacturing system lean?
– the 3 M’s of lean
• muda – waste
• mura - inconsistency
• muri - unreasonableness
Value stream
mapping
• Follow a “product” or
“service” from beginning to
end
• Draw a visual representation
of every process in the
material & information flow
 Value Stream Mapping

Helps us see where value is created, and

where waste exists:

• A visual approach, by “product family”

• Shows flow of both material & information
• Helps us see which specific Lean tools can
be used to improve flow and eliminate
waste
• Two maps will be made: Present State
(“how it is”) & Future State (“how it should
be”)
 Value Added vs Non-
Value Added
• Value added: Transforms raw
material and information into
products or services to be marketed

• Non-value added (waste):

Consumes resources but does not
contribute directly to the product or
service to be marketed
7 Deadly Wastes
What is 5S?
• Represents 5 disciplines for
maintaining a visual
workplace
1)Sort
2)Set in Order (Stabilize)
3)Shine
4)Standardize
5)Sustain
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 Elements of a 5S
Program
• Sort—Perform “Sort Through and Sort Out,” - red tag
all unneeded items and move them out to an
established “quarantine” area for disposition within
a predetermined time. “When in doubt, move it
out!”
• Set in Order—Identify the best location for remaining
items and label them. “A place for everything &
everything in its place”.
• Sweep (Systematic Cleaning)—Clean everything,
inside and out. Use visual sweeps to ensure
everything is where it should be and that junk is not
accumulating.
• Standardize—Create the rules for maintaining and
controlling the first 3 S’s. Use visual controls.
 Who wants what…

Cash !!

Value !!
Customer
Low Cost Your Company
High Quality Profit
Availability Repeat Business
Growth
Potential Benefits
of Lean
• 90% reduction of production times
• 50% increase in productivity
• 80% quality improvement
• 75% improvement in space utilization
• 85% reduction of "work in progress"
(stuff waiting to be finished)
• And reduction of material waste

= COST SAVINGS
Before 5S
After 5S
After 5S
After 5S
 Comparison of
Traditional vs. Lean

Traditional Lean
• Complex • Simple and
• Forecast Driven Visual
• Excessive • Demand Driven
Inventory • Inventory as
• Speed Up Value- Needed
Added Work • Reduce Non-
• Large Batch Value-Added
Production • Small Lot Size
• Long Lead Time • Minimal Lead
THANK YOU