Dr. R.GNANAGURU, M.E.,M.C.A.,M.B.A.,Ph.D., Professor, Department of Mechnical Engineering, Dhirajlal Gandhi College of Technology, Salem. email: saiguruhema@gmail.

com
email: saiguruhema@gmail.com

LEAN EARLIER SCENARIO Price = Cost + Profit

CHANGED SCENARIO
Profit = Price Cost

TO ACHIEVE & GET SUCCESS Lean manufacturing or simply LEAN is one of the best options available.
email: saiguruhema@gmail.com

LEAN

LEAN
REMOVAL / ELIMINATION OF WASTE IN ANY PROCESS

WASTE
Anything that adds COST to the product without adding VALUE -UNAVOIDABLE WASTE & (AVOIDABLE WASTE)

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TIME LINE OF LEAN

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Waste

Seven wastes 1. Transport 2. Inventory 3. Motion 4. Waiting 5. Over Production 6. Over Processing 7. Defects
8. Skills utilisation Taiichi Ohno

Value Added: 5%

Non - Value Added: 95%

email: saiguruhema@gmail.com

Waste
Waste of Waiting
Lean in Education Waiting for Faculty. Waiting for Lab instrument. Waiting in Library. Waiting in Canteen.

Waiting for Test results.

Operators standing idle

Having to stand around waiting for the next processing step, tool part, etc. Having no work because of no stock, batch processing delays, equipment downtime, and capacity bottlenecks.

email: saiguruhema@gmail.com

Waste
Waste of Transporting
Lean in Education Part & Product = Books & Files Location of Photocopying department

Delivery of lessons via internal mail.

Location of Labs, Workshops & Stores. Location of Library. Online Practical evalauation (S/W). Paper less office.

Moving parts and products unnecessarily

Moving WIP from place to place in a process, even if it is only a short distance.
Having to move materials, parts, or finished goods into or out of storage or between processes.

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Waste
Waste of Over production
Lean in Education Product = Student Multiple coppies of handouts. More number of assignments. More number of manuals. More students enrolled than labour Market needs to meet its demands.

Producing items earlier or in greater quantities than needed

Producing earlier or more than needed generates other wastes, such as
overstaffing, storage & transportation costs because of excess inventory. The worst form of waste because it contributes to the other six.

email: saiguruhema@gmail.com

Waste
Waste of Motion
Lean in Education
Students and lecturers travelling to multi sites, to different classrooms, throughout the same day.

Poor layouts restricting the movement of the lecturer around the students.

Operators making movements that are unnecessary

Any motion employees have to perform during the course of their work other

than adding value to the part, such as reaching for, looking for, or stacking parts,
tools etc. Walking is waste

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Waste
Waste of Defects
Lean in Education
Students not achieving the required learning outcomes (Failures).

Wrong results identified at the end of the practical session. Regular feedback from the students, not end of the semester. Regular class tests.

Not working right first time Repairing of rework, scrap, replacement production, and inspection means wasteful handling, time and effort.

email: saiguruhema@gmail.com

Waste
Over Processing
Lean in Education Over assessment. Co-curicualr and Extra-curicualr activiteis. Special classes. Students undertaking additional subjects to get the next job. Out of syllabus topics.

Taking unneeded steps to process the parts.

Inefficiently processing due to poor tool and product design, causing
unnecessary motion and producing defects. Waste is generated when providing higher quality products than is necessary.

Waste
Waste of Inventory
Lean in Education Inventory = Students Raw material = Admitted students Work In Progress = Studing students Finished goods = Graduated students

Having more than the minimum stocks necessary

Excess raw material, WIP, or finished goods causing longer lead times, damaged goods,

transportation & storage costs, and delay.

Extra inventory hides problems such as production imbalances, late deliveries from suppliers, defects, and long setup times

Lean in Education

Thank you.....