Lean Manufacturing 53e14

Lean Manufacturing PRESENTED BY SUSHEEL DUBEY(10) ASIYA SHAIKH(32) MIHIR JANI()

Definition of Lean Manufacturing 

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Lean manufacturing is a comprehensive term referring to manufacturing methodologies based on maximizing value and minimizing waste in the manufacturing process. Value is defined as an item or feature for which a customer is willing to pay. All other aspects of the manufacturing process are deemed waste. Lean manufacturing is used as a tool to focus resources and energies on producing the value-added features while identifying and eliminating non value added activities.

Goals of Lean Manufacturing Get ever closer to zero Zero

waste Zero defects Zero scrap Zero rework Zero receiving rejections Zero downtime Zero inventory Zero handling Zero paperwork Zero mistakes

Get ever closer to zero process times Setups Sales quotes Delivery date promising Sales order delivery Production process time Purchase order lead times Outsourcing Engineering changes Time to market Returns Repairs Data collection Data analysis

Origin Of Lean Manufacturing 

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The Industrial Revolution marked the emergence of lean thinking in operational practices, such as standardization of methods and materials, interchangeability of parts, specialization of labor, large batch operations, and dedicated machinery. These operational practices were used only in manufacturing processes for high-volume products. Henry Ford provided the first industrial firm that had traces of lean manufacturing (main assembly line and key subassemblies). Originally a Japanese methodology known as the Toyota Production System designed by Sakichi Toyoda, lean manufacturing centers around placing small stockpiles of inventory in strategic locations around the assembly line, instead of in centralized warehouses. These small stockpiles are known as kanban, and the use of the kanban significantly lowers waste and enhances productivity on the factory floor.

Mass Production Vs. Lean Production General Motors 40.7

Toyota

Adjusted assembly hours per car

31

16

Assembly defects per 100 cars

130

45

Assembly space per car (sq. ft)

8.1

4.8

2 wk

2 hr

Gross assembly hours per car

Inventories of parts

18

Waste associated with Mass Production 

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Over-Production Waste Fixing Defects Waste Unnecessary Motion Waste Inventory Waste Over-Processing Waste Transportation Waste Waiting Waste

Steps to reduce or eliminate waste “Lean Manufacturing” 

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Organize the workplace (5S) Arrange everything to “flow” Make small batches (ideal lot size is 1) Introduce pull systems (self-correcting control) Never stop continuous improvement

Traditional

World Class “Lean”

Organization

Complex, functional departments

Simple, product focused

Employees

Individuals

Teams

Scheduling

Forecasts

Actual demand

Production

Push, batch, big lot

Pull, flow, small lot

Maintenance

Reactive

Proactive

Quality

Detection & correction Prevention

Control

Reports, supervision, blame-oriented

Visual Scorecards, teams, goal-oriented

Relationship Between Lean and Six Sigma Important point for companies is to first determine goal, and then adopt and apply the appropriate strategy in order to achieve the goal.

Lean Waste

elimination Work concentration Flow

Process-based Reduce Cycle time

Initiative Tactical Objectives Improvement Project Characteristic

Goal

Six Sigma Variation

reduction Rework & scrap elimination Process Control

Product-based Improve Quality

Why is Lean Manufacturing Important? 

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Many companies have turned to lean techniques as a way to achieve lower costs and more factory throughput. The most progressive companies, seeing the astonishing success that lean provides on the shop floor, have begun to apply lean methods to the entire supply chain. Companies that understand the evolving enterprise know that every step in the supply chain, even those that occur at the customer or supplier, has to be examined using lean techniques in order to achieve the maximum benefits. These companies find that they not only survive in difficult times, but they actually thrive and gain market share as their competition falls behind.

How does Lean affect Project Management? 

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As interest in lean production grows, this vocabulary engineering is also accompanied by scope creep: what started out with a focus on the factory expands to cover product design, office work, distribution, and services. And new follow: Lean Management Lean Enterprise Lean Thinking Lean Performance Project Management Lean Product Development

QUESTION 

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THANK YOU