What is “Lean

Manufacturing?”
• Lean manufacturing is aimed at
elimination of waste
• Organize processes to add value to
the customer
• Deliver goods “just-in-time”
• Service organizations also using
lean
Basic Lean Principles
• Add nothing but value
– Eliminate “muda” – waste
• Do it right the first time
• People doing the work add value
– Team oriented
• Deliver on demand
– “Pull” instead of push
 History of Lean
• “The Machine That
Changed the
World”
• Toyota auto
manufacturing
• “Value chain”
 Waste Categories
• Overproducing
• Inventory
• Waiting
• Extra Processing
• Correction
• Excess Motion
• Transportation
• Underutilized
People
 OVERPRODUCIN
G
To producer sooner, faster
or in Greater quantites than
customer demand.
 INVENTOR
Y
RAW MATERIAL WORK IN
PROGRESS OR FINISHED
GOODS WHICH IS NOT HAVING
VALUE ADDED TO IT.
INVENTOR
Y
 WAITING
PEPOLE OR PARTS THAT
WAIT FOR A WORK CYCLE TO
BE COMPLETED.
WAITING
 TRANSPORTATIO
N
UNNECESSARY MOVEMENT
OF PEOPLE ,PARTS OR
MACHINES WITHIN A PROCESS.
 REWORK
Non right first time
,Repetition or correction of a
process.
 OVER
PROCESSING
Processing beyond the
standard required by the
customer.
8th WASTE
Potential of people
 Flow Process Charts for Data Recording
This chart uses This chart is of 3 types:
circles for operations  Man – Activities of operator
arrows for transports  machine - Manner in which the
squares for inspections equipment is used
 triangles for storage  Material - the changes the material
letter D for delays. undergoes in location or condition
Before Layout Revision Process
Sl.
Operation M achine
No
.
From In
After Layout Revision Process
1 Storage
trolley Sl.
Operation Machine
2 Coining Press No.
Storage + Relief In
3
Plug Assy.
Trolley 1 Storage
trolley
4 Ball Pressing Press
2 Coining Press
On the
5 Storage
Machine
3 Bearing Pressing Press
6 Leak Check Air Gauge

7 Storage Table 4 Ball Pressing Press

Poppet
8 Table Leak Check&
assembly 5 Table
Bearing Poppet Assy.
9 Press
Pressing Thrust washer Poka-
6
10 Storage Table Assy. Yoke
11
Thrust washer
Assy.
Poka-Yoke Total 1 5 0 0 0

12 Storage --

Total 6 6 0 1 4

Vertical lines connect these symbols in the sequence they are performed.
BEFORE
Before Layout Revision Process
Sl.
No Operation M achine
.
From In
1 Storage
trolley

2 Coining Press

Storage + Relief
3 Trolley
Plug Assy.

4 Ball Pressing Press

On the
5 Storage
M achine Storage - 6
6 Leak Check Air Gauge Process - 6
7 Storage Table
Inspection - 1
Poppet
Waiting - 4
8 Table
assembly
Bearing
9 Press
Pressing

10 Storage Table

Thrust washer
11 Poka-Yoke
Assy.

12 Storage --

Total 6 6 0 1 4

inspection
storage
operation waiting
transportation
AFTER
After Layout Revision Process
Sl.
Operation Machine
No.
In
1 Storage
trolley
2 Coining Press

3 Bearing Pressing Press

4 Ball Pressing Press

Leak Check&
5 Table
Poppet Assy.
Thrust washer Poka-
6
Assy. Yoke
Total 1 5 0 0 0

Storage - 1
Process - 5