LEAN MANUFACTURING

Group 10

Presented by:
Mamun
Sreejith
Srinivas
Suhas
Sumit
WHAT IS LEAN MANUFACTURING?

 Lean is an approach to achieving manufacturing

excellence based upon the continued elimination
of waste. Waste is defined as activities that do
not add value to the product.

 A systematic approach to the identification and

elimination all forms of waste from the value
stream.
LEAN MANUFACTURING
 Theconcept of Lean Manufacturing was
developed by Henry Ford in 1920’s

 Toyota
was the first company to introduce ‘lean
manufacturing’ concept in its production system.

 Lean manufacturing focuses on reducing waste.

CONTD..
 Evolution

 Pull from demand

 Technology

 Fulfillment
TYPES OF WASTE
 OVERPRODUCTION

 INVENTORY

 WAITING

 MOTION

 TRANSPORTATION

 RE-WORK

 OVER-PROCESSING
BENEFITS OF LEAN MANUFACTURING
 Lower production cost  higher profits and
wages
 Cost avoidance flows directly to the bottom line

 Supports ISO 14001 and "green"

manufacturing
 Reduction of material waste and associated disposal costs
 higher profits

 Shorter cycle times: make-to-order vs. make-

to-stock
CONTD..
 Productivity Improvement
 Total manufacturing time saved

 Less scrap

 Low inventory

 Quality improvement

 Plant space saved

 Better labor utilization

 Safety of operations
PRINCIPLES OF LEAN MANUFACTURING
• To create continuous flow .
• To use pull-systems to manage the workflow
• To reduce batch sizes and inventories
• To eliminate waste
• To cross-train workers in order to deal with
inherent variability
• Selective use of automation
• To instill a Continuous Improvement
competence
5S - WORKPLACE ORGANIZATION

 A safe, clean, neat, arrangement of the

workplace provides a specific location for
everything, and eliminates anything not required.

In Lean manufacturing, we refer to this as 5S.

ELEMENTS OF A 5S PROGRAM
• Sort—Perform “Sort Through and Sort Out,” -
red tag all unneeded items and move them out to
an established “quarantine” area for disposition
within a predetermined time. “When in doubt,
move it out!”
• Set in Order—Identify the best location for
remaining items and label them. “A place for
everything & everything in its place”.
CONTD..
• Sweep (Systematic Cleaning)—Clean
everything, inside and out. Use visual sweeps to
ensure everything is where it should be and that
junk is not accumulating.
• Standardize—Create the rules for maintaining
and controlling the first 3 S’s. Use visual
controls.
• Sustain—Ensure adherence to the 5S standards
through communication, training, self-discipline
and rewards.
COMPARISON OF TRADITIONAL VS.
LEAN
Traditional Lean
Complex Simple and Visual
Forecast Driven Demand Driven
Excessive Inventory Inventory as Needed
Speed Up Value-Added Work Reduce Non-Value-Added
Large Batch Production Small Lot Size
Long Lead Time Minimal Lead Time
Quality Inspected-in Quality Built-in
Functional Departments Value Stream Managers
IMPLEMENTATION STAGES OF
LEAN MANUFACTURING

Three stages in the implementation of ‘Lean

Manufacturing’---

 Data collection stage

 Data analysis and development of solution Stage

 Implementation Stage  
PROCESS OF IMPLEMENTING LEAN
MANUFACTURING
FLEXIBLE RESOURCES
 Multifunctionalworkers
perform more than one job
general-purpose machines perform several
basic functions

 Cycletime
time required for the worker to complete one
pass through the operations assigned

 Takt
time
paces production to customer demand
CONCLUSION
 Business activities can contain enormous
quantities of built-in waste (muda, friction).
 The greatest obstacle to the waste's removal is
usually failure to recognize it.
 Lean manufacturing includes techniques for
recognition and removal of the waste.
 This delivers an overwhelming competitive
advantage.
Thank You