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Lean Assignment 1

Lean Assignment 1

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Published by Vinoth Palaniswamy
This is an essay about lean and current state mapping of provided company. This will give you an over view to approach lean.
This is an essay about lean and current state mapping of provided company. This will give you an over view to approach lean.

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Published by: Vinoth Palaniswamy on Mar 15, 2011
Copyright:Attribution Non-commercial


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Lean assignment -1Summary:
This document will give a good view of manufacturing via lean. Most manufacturingcompanies have already started approaching lean manufacturing system. The mainobjective of lean methodology is to reduce waste and aims at supplier integration forthe common achievable goal in manufacturing by reducing the non value added time. i.e,raising ratio of value added time to non value added time and waste. Here the case of aautomotive manufactures is considered after some serious trouble in business. Themanufacturer after losing few successive business and with some serious issues, look forward for lean implementation.The current state mapping analysis gives the current process flow and the level of inventory at various product families. And with this the future mapping is to be drawnfor some serious implementation which will focus and resolve all the current state map.
Introduction of the Organisation:
M Automotive parts (MAP) is one leading manufacturing company, located at Midlands.They are first tier supplier to automotive industries. With the current trend of massproduction, they lost two major orders to overseas competitors, along with employeeredundant of 20%.
Lean Introduction:
Lean manufacturing is a variation on the theme of efficiency; it is a present-day instanceof the larger recurring theme in human life of increasing efficiency, decreasing waste,and using empirical methodsLean principles come from the Japanese manufacturing industry.Lean is nothing but is set of tools that elimination of waste. As waste is eliminatedquality improves while production time and cost are reduced.Examples:Value Stream Mapping
Pull systemsPoka-yokeToyota production system follows the lean operation principles. Whose goal is cost reduction by the elimination of waste these principle is nothing but pull processing,Pull processing:a)
Perfect first-time quality,b)
Waste minimizationc)
Continues improvement d)
Building and maintaining a long term relationship with suppliersf)
Automation load levelling and production flow and visual controlLean implementation is mainly focused on getting the right things, to the right place, at the right time, in the right quantity and minimizing waste.
Seven Wastes of Lean:
As learned, lean is a tool eliminate waste in any form in chosen sector. Waste meanperformances that consume time, capital and space, but do not contribute to fulfillingcustomer needs. They are classified under the following categories.
Over production
: Considered as greater source of waste2
iting time
: This is time spend waiting by labour or equipment waiting to add value to theproduct
: Unnecessary transportation of WIP is another waste
: Operations that do not add value, but are done just due to some poor work (i
: Inventory of all types
: Unnecessary movement of man and material
efective goods
: Total cost of poor quality could be high, includes poor quality and scrapmaterial, waste of labour time, and time expecting orders
ools and
echniques of Lean:
Lean aim is to reduce the waste, mean if we do any work it is simple sufficient torecognize, to do and to manage. Lean is help to short methods to produce the product inright way and reduce waste and cost reduce more with less time, inventory, space,people, and money.The manufacturing process is depended on the lean techniques that are being used toimprove the production process. Those techniques are based on the followingapplications:
Value: the main information is taken from what and up to what amount thecustomer is willing to afford to buy that object.
The value stream: this gives us the information about the processing steps that are used to remove the non-value work processes from the designing process tothe usage of the customer.
Flow: this removes the wastage from the process without any obstacles. The flowcan be reduced for inventory and expertise.
Pull: it is the way in which we can make the lining of the products as well as theprocesses from the production process based on the usage of the customer.
Perfection: it is the way of motivating to get the things done right the in the first time by using the application of continuous improvement.By following lean techniques we can easily identify the places of Non-value added timeand then accordingly the yamazumi board is drawn and from which, we can calculatethe takt time.The most commonly accepted and used few tools are,
alue Mapping
: Value stream mapping is tool typically used during lean initiatives topresent pictorially the flow of material and information as a product or service makesits way through the value stream. A value stream map is often used to identify where tofocus future improvement efforts to reduce or eliminate non value added activities,cycle time and costs.

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