Lean Manufacturing Practices

Lean is about
Doing more with Less
* Less Inventory
* Less People
* Less Space
* Less Money
* Less Time (More Speed)
* Less Wastage arising due to
- Input Variability
- Process Variability
- Demand Variability
 Focus of Lean Manufacturing

* Continue Process Improvements

* Elimination of Waste
- Non Value Added Work
 Lean Manufacturing Using 5
processes
* Value --- what Customer is willing to Pay
* Value Stream --- Mapping and Identifying actions
required to eliminate
- Non Value Adding Activity
- Right from design to customer usage (end to end)
* Flow --- Elimination of all obstacles to make Value
Streams flow without interruption
* Pull- link between Product and Process to facilitate
product usage by customers
* 1st time right --- faster cycle times
Pre-requisites for Lean Manufacturing

* Equipment Reliability
* Balanced or Leveled Production
* Use of J-I-T
* Matching Human Skills with Technology
 Likely Road Blocks

* Complacency ---- No reason to Change ( I am OK)

* Downsizing under the pretext of Lean
Manufacturing
* Inadequate conviction at Middle Management /
Workers level
* Inadequate roll clarity (MOP not clear)
* Trade off between short and long term focus
* Lack of continued support from Top Management
 Key Success Factors
* Communicate the Vision --- Everyone to
understand the need for change
* Facilitate usage of Lean Management Techniques
like J-I-T
* Set Standards --- Use TQM and 5S Concept
* Help everyone adopt new processes (training and
development)
* Measure performance as per Standards (3rd Pt)
* Constant focus on upgradation (Kaizen)
 Expected Benefits
* Faster Cycle Times
- Product development time for a new vehicle
reduced from 3-4 yrs to 1 yr.
* Lower Inventory
- Inventory turns to go up from 3-4 to 12-15 a year.
* Reduce Cost
* Space Utilization ---- Reduce to 50%
* Less Material Movement
* Less Scrap and re-work
- due to focus on 1st time right