1/1/2013

C+LEAN=CLEAN

By-
Manoj Tiwari
DFT/NIFT-G’Nagar

Important Points…

A. There are only 14 slides (effectively 11)

B. 1, one minute movie clip
C. A small presentation
D. Point number B and C are not mine…!!!
E. and a set of questions from you…!!!

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Copyright © Manoj Tiwari 2010

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What's LEAN…
And more important is how…
C*+LEAN= CLEAN

* C means Complete

So…
If we go for Complete LEAN, it can make our life
(personal & professional both) Clean…
…Clean from all types of WASTAGES…!!!
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Copyright © Manoj Tiwari 2010

LEAN is all about…

 Identification, reduction or if possible
Elimination of Wastages from the processes.
 Leaving OLD & BAD habits and adopting NEW &
BETTER habits.
 Improvement in overall effectiveness
 Optimisation of resource usage
 Achieve excellence or even perfection in every
aspects of the enterprise by continual
identification/reduction/eliminate waste
 And….Continual Improvement…!!!

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Copyright © Manoj Tiwari 2010

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LEAN Thinking…
It’s a philosophy…a way of life style
And…

Its all about Common Sense…

…Which is probably Most Uncommon…!!!

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LEAN Thinking…
To identify any wastage in a process…we must
know…
1. What is Value Addition (VA)…?

2. What is Non Value Addition (NVA)…?

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Value Addition (VA)…

LEAN philosophy says, the activity needs to be
evaluated on 3 parameters.
If all three conditions are satisfied…the
activity/process is Value Added (VA)
otherwise it’s Non Value Added (NVA).

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Copyright © Manoj Tiwari 2010

The 3 Conditions…for VA…

 There must be a Phase transformation in
the product by doing this activity or process.
 The change due to this processing or activity
should be aiming to achieve the quality
standards as required by the buyer.
 Buyer should be ready to PAY for it.

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Copyright © Manoj Tiwari 2010

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Types of MUDAS*…
*MUDA is a Japanese word, synonymous to waste, There are 8 types
of MUDAS as per LEAN philosophy…

Muda of… 5. Over Processing

1. Transportation 6. Inventory
2. Motion 7. Over Production and
3. Waiting 8. Excess Man Power
4. Rework

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Copyright © Manoj Tiwari 2010

Wastage…Some facts…
Researches done at Lean Enterprise Research
Center (LERC), UK reveal that in a
manufacturing set up, avg. share of Non
Value Added activities is* -

* Peter Hines & David Taylor: Going Lean, Lean Enterprise Research Centre, January 2000
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Wastage…Some facts…
 At present Mass Production Plants devote 20% of
plant area and 25% of their total Hours of efforts
to fixing mistakes*.

* Womack James P., Jones Daniel T., Roose Daniel, “The Machine That Changed The World”, The
rise of Lean Production, Ch. 3, pp. 57

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Copyright © Manoj Tiwari 2010

Types of MUDAS and LEAN tools…

THM Muda
of
Manpower
Step-9
1 PC. FLOW
Muda of Over
production
Step-8
KANBAN
Muda of Inventory
Process Standardization Step-7

Muda of Over processing

5S, TFM, TPM, TQM Step-6

Muda of Rework
TPM, TQM & Step-5
KAIZEN
Muda of Waiting
Step-4
TFM
Muda of Motion
5- S Step-3

Muda of Transportation
Hands on Step-2
Training
Lack of awareness of LEAN tools
Step-1
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Copyright © Manoj Tiwari 2010

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If we analyze carefully…
Our life is also full of MUDAS…
1. Waiting at govt. offices ( Now ERPs are there)

2. Banks (Now ATMs are there)

3. Railway ticket counters (Now online booking is

there)
4. At Home- Keeping Stock for whole year

5. Hospitals

6. Extra and unused manpower sitting/sleeping

everywhere…
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Copyright © Manoj Tiwari 2010

Thank
For more details, pls. follow- you…
http://www.fibre2fashion.com/industry-article/29/2842/look-at-your-business-through-lean-lens1.asp
“Look at Your Business with LEAN Lens” by Manoj Tiwari

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Copyright © Manoj Tiwari 2010