Professional Documents
Culture Documents
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Lean.
Way. Introduced by Womack & Jones. Lean is a concept that centers on waste elimination . Aims to make the work simple enough to understand, to do and to manage. Improves business performance using simple, practical tools and techniques to enhance quality, cost, delivery & people contribution.
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requirements
Identify the value stream: Identify the process from product design to
Make the product flow: Identify the bottlenecks within the process Produce at the Pull of customer: Make the products to meet customers In pursuit of perfection (Continuous Improvement)
needs and requirements, and make it available when the customer wants it
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Aims of Organisation
To improve competitiveness To reduce wastage To improve quality
To produce faster
To reduce cost and maximize profits
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Lean Manufacturing
Management philosophy derived mostly from Toyota
Production System but also from other sources. A systematic approach to identify and eliminate waste through continuous improvement by flowing the product at the demand of the customer." Optimizing people,space,processes,activities, materials and resources.
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Continued..
Creates a culture of : Using less material Creating less waste Using less resources,water,energy etc Quality and safety Continual improvement.
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adopted it It incorporated the Ford production process In 1990, James Womack introduced the word LEAN MANUFACTURING in his book THE MACHINE THAT CHANGED THE WORLD
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Overproduction
Over Processing
Processing beyond the standard required by the customer.
1 7
Inventory
2 3
Rework
Raw material, work in progress or finished goods which is not having value added to it.
Waiting
People or parts that wait for a work cycle to be completed.
Transportation
Motion
removed.
To identify the different forms of that waste & causes.
To find solutions for the identified root causes. Implementation and maintenance.
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1. Cellular Manufacturing
Reduced lead time and "in-process inventories" Simplified process flow layout Eliminating overproduction Reduced set-up and changeover times Enhanced visibility and easier identification of
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2. Kaizen
1. Identifying the problem by going to the source / workplace.
2. Take temporary steps to solve the problem. 3. Collecting primary data to analyze and solve the problem. 4. Implement the solution and standardize work processes to prevent its future occurrence.
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3. 5 S tools
Seiton - Sort or Simplify: Remove unnecessary items from the work area
Seiso - Scrub or Shine: Repair, clean and keep clean Seiketsu - Standardize or stabilize controls Shitsuke - Sustain or Self discipline:Strive for continuous improvement
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4. JUST IN TIME
Manufacturing and conveying
What is needed When it is needed The amount that is needed At the quality required In the shortest possible lead time
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5. Production Smoothing
Production runs take place in large batches to
minimize set-up / changeover time losses, and achieve high production efficiencies.
The process of Heijunka or smoothing synchronizes
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6. Pull System
Pull system rely on the customer order pulling
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7. Poka -Yoke
Poka:- inadvertent errors
Yokeru:- to avoid
pass downstream
Poka yoke is a mechanism that prevents a mistake