LEAN

BY
KARTIK SINGH
M/BFT/11/10

Objectives
Definition and history

8 types of waste
Tools
Case study

Lean
A method of streamlining a process, resulting in
reduction in waste, costs and maximizes value addition
to the product.

Evolution

Lean Principles

8 wastes

Benefits:
Identifies problem areas and bottlenecks

Increases business efficiencies make sure staff

Time is spent on valueadded activities.
Save money reduce overhead in paperwork

Simplify processes
Conform to rules & regulations and codes of
Conduct standardizing processes using Lean

Lean tools
5S
Value Stream Mapping
Standardized Work
SMED
Kaizen
Kanban
Poka-yoke
Cellular Manufacturing
One Piece flow production

Case study
Garment manufacturing unit based in Bangladesh
Problems:
High WIP ,
style change over time was more

Order quantities as small as 50-100

More style changes
Low factory efficiency
As low as 30-35% compared to 55-80 normally
Requires flexible manufacturing systems
No time for proper balancing the line
Quick set-up changes needed

WIP fluctuation within production lines is very high with CV% ranging from 79.2
to 165.6

Implementation Process
Company had 20 production lines

Initial implementation on 1 line

No capital investment required
Line divided into sub-cells
Changing of operators and management attitudes key
Gaining trust of process operators.
General use of Lean tools and Techniques including 5S, Visual

controls, Poke Yoke, and SPC

Designing Cells
Previous
layout

New layout

Sub-cells of 5 -10 implemented

Sub-cell balanced using pitch time thus regulation the WIP

Results
1. Making the Flow Smooth
Sub cell designed to promote work sharing
Problems shared to prevent WIP fluctuation
Improved incentive scheme, no piece work

2. WIP Reduction within the line

Ply quantity size gives high WIP at start of line.
Large cost when applied to a number of line

3. Improved Quality Level

Quality owned in the sub cell
Standardised approach required for all staff new and existing
Visual aids provided at cell level including examples and photos
Mistake proofing principle applied.

4. Replace Balancing
Balancing done by sub cell operators
They take into account absenteeism, quality issues and breakdowns.
Higher motivation has seen slight reductions in absenteeism

References
http://www.c4mbd.com/Documents/The_8_Wastes_of_Lean_

Management_Aid_Memoir_A4.pdf
http://www.goleansixsigma.com/8-wastes/
www.business2community.com
www.leanprimer.com/downloads/lean_primer.pdf
http://www.theseus.fi/bitstream/handle/10024/34405/Paneru_
Naresh.pdf
http://www.slideshare.net/JAMES_MARSH/case-study-srilanka-lean-wip-reduction