Overview

of
Lean Manufacturing

October 23，2023
At Kickoff Meeting for Demonstration Companies Project
in Pakistan
Contents
1. What is Lean Manufacturing(LM) ?
2. Contents of LM
3. Detail of LM
1) Eliminate waste
2) Continuous flow production
3) ”Heijyunka” Production leveling
4) Standardized work
5) Multi-skilled workers
6) Just in Time
7)”Kanban”
8)”Jidouka” Autonomation
4. Implementation of LM

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1. What is Lean Mnufacturing?

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What is Lean Manufacturing?
➢In late 1980s, Dr. James P. Womack (professor in MIT)
and his project members studied about Toyota Production
System (TPS) in order to find out the competitiveness of
Japanese automobile industry, and summarized it as
“Lean Production System.”
➢They introduced it to the world in English as the most
efficient production system, under the title “The Machine
That Change the World.”

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Relationship with TPS

➢ “Toyota Production System (TPS)” is a unique

production system created and developed by
Toyota Motors Corp. in Japan.
➢ It is a production system for many models in
small quantities that reduces working hours,
inventories, etc. drastically while improving
quality by streamlining the process control
thoroughly.
➢ TPS is not tool or method, it is philosophy and
“way of thinking” of production system.
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Benefits

➢ Typically LM will improve:

⚫ Cost reduction
⚫ Quality performance
⚫ Fewer machine and process breakdown
⚫ Lower levels of inventory
⚫ Greater levels of stock turnover
⚫ Less space required
⚫ Higher efficiencies, more output per man-hour
⚫ Improve delivery performance, etc.
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2. Contents of Lean Manufacturing

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 Objectives & Items

➢ Three Objectives of LM
1. To reduce “Production Cost” by eliminating waste
2. To shorten “Production Lead Time”
3. To manufacture “High Quality Product”
➢ Basic items (two pillars) of LM
1. “Just-in-Time” (JIT)
Producing right amount of products at right time
2. “Jidoka” Autonomation
Automation with human intelligence
Based upon basic activities such as 5S, Kaizen,
QC, etc.
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Structure of LM

Lean Manufacturing

Just-In-Time Continuous Kaizen Jidoka

(JIT) Autonomation
✓ Kanban Waste reduction ✓ Andon
✓ Pull system 7 wastes ✓ multi-machine
✓ Continuous flow handling
3M
✓ SMED ✓ “Poka-yoke”
“Muri”, “Mura”, “Muda”
“Heijyunka” Production leveling, Standardized work
TQC (Total Quality Control), QCC activities
5S (sort, set in order, shine, standardize, sustain)
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Two maijor items of LM

Just-In-Time (JIT)
◼ To produce products with “just what is needed”, “only
when needed”, “only in the quantity needed.”
◼ To reduce extra inventory by supplying only necessary
quantities of parts on time.

“Jidoka” Autonomation
◼ Autonomation means, “Adding human intelligence to
automated machine.”
◼ Machine stops automatically whenever it detects anything
abnormal to avoid making defects.
◼ Workers need not to keep watching machines all the time.
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Target of LM

Basic concepts Methods Targets

• Continuous flow &
production leveling
Cost reduction
• Pull production system
by waste
Just-in-Time • SMED
elimination
(JIT) • Standardized work
• Kanban method Shorten
production
• Machine stop & notify
abnormality lead time
“Jidoka” • Operation condition
presented by Andon
Autonomation High quality
• Built-in quality (Poka-
yoke) products
Kaizen (Continuous improvement)
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3. Detail of LM

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 1) Elimination of wastes
➢ 3M “Muri”, ”Mura”, ”Muda” are the elements
to be get rid of
Handling a 20kg carton
⚫ “Muri” box in the work place

overburden  Carrying a box by worker

Priority to eliminate
himself is “Muri”=overburden
unreasonableness →he may hurt his back
⚫ “Mura”  Handling a box sometimes by
unevenness forklift, sometimes by handcart is
inconsistency “Mura”=unevenness
→handling should be done by
unbalance same method
⚫ “Muda”  Handling a box by forklift is
waste “Muda”=waste
unnecessarily →useless to use forklift in this case
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1-1) 7 types of wastes
➢ There are seven types of “Muda” wastes observed
in the work place.

1. Overproduction 2. Waiting 3. Transportation

4. Processing 5. Inventory 6. Motion 7. Defects

Target of LM is to “eliminate all kinds of waste”

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 2) Continuous flow production

➢ The essence of LM for production line is to

create continuous flow.

Batch production
Traditional method with WIP: in-
process
work-in-process (WIP) inventory

transport
Continuous flow production
Continuous flow production
is to carry out one piece flow,
eliminating WIP
No WIP
No transport
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 3)“Heijyunka” Production leveling
Traditional method of Fabricating by
fabricating in order of type production leveling
Average fabricating time = 51.3sec Takt time = 48 sec
Fabricating time (sec)

60 60
“Mura”
51.3 Unevenness 51.3
48
40 a a a a a a
40 a a a a a a
b b b b b b b b
c c c c c

Fabricating order Fabricating order

• Since takt time < average fabricating time, overtime work
would occur to meet daily demand.
• Countermeasures should be taken to reduce fabricating time,
priority is car type a. 16
3-1) “Heijyunka” Production leveling

➢ Another purpose of “Heijyunka” is to make

production volume as constant as possible so
that there is no big difference in the quantity of
parts withdrawn.
Leveled

Production
quantity Maximum
Minimum

Time
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 4) Standardized work

➢ Standardized work is an organized human motions

to create an efficient production sequence without
any “Muda” Waste.

Takt time

Standardized work Work sequence

Standard in-process-stock

Standard work documents

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 5) Multi-skilled workers
➢ Shop workers play a particular role to perform
many different jobs by operating diverse types of
machine and equipment in LM.
➢ These workers can easily perform jobs outside of
their normal assignment if production volume has
changed.
➢ Such workers are multi-skilled workers who can
handle multi-machines or multi-processes.
➢ One of the objectives of human factor of LM is to
cultivate multi-skilled workers.
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6) Just In Time

➢ All items described in the previous sessions are the

basis of JIT structure

JIT
Production leveling

SMED One-piece flow at

Reduction of synchronized line
setup time

Machine Multi- Standardized

skilled
layout worker work

Elimination of wastes
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6-1) Benefits of JIT

1. Reduction of lead time

2. Delivery time reduction for customer
satisfaction (CS)
3. Reduction of products inventory
4. Reduction of work-in-process
5. Minimize dead product inventory even if there
is a model change

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7) Kanban

➢ The word Kanban means advertisement board

or visual sign in Japanese.
➢ Introducing Kanban in production line is a
method to realize JIT.
---- To prevent overproduction
---- To adjust production variables
➢ Kanban is a visual signal, made of a sheet of
paper in a vinyl folder, that
is used to trigger action.

Example of Kanban
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7-1) Utilization of Kanban

Production kanban Withdrawal kanban

Storage Storage
Pull ①
Mechanical processing line
Pulled
processing
④

⑤
③
②

Despatching table Post of production

Kanban
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 8) “Jidoka” Autonomation
“Jidoka” “Jidoka”
Autonomation Automation
Machine checks Machine keeps operating
abnormalities and stops unless operator turns off
when detected the switch

No transfer of defects Delay in detection of defects

Prevention of machine Might cause machine

breakdown breakdown

Easy to find causes of Difficult to find causes

abnormality at the earlier stages
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 8-1) Essence of “Jidoka”

➢ Main portion of “Jidoka” is to find the root cause of

breakdown and defect that stopped the machine and
take countermeasures so that same trouble will never
happen again.
➢ Never leave the problem unsolved or otherwise it will
happen again.
• Whenever a red lamp is lighted at ANDON, then supervisor,
leader and workers gather around the corresponding machine.
• Ask 5 why’s to get to the root cause.
• Then countermeasures of the root cause are performed, and
these are put into other similar type of machine to avoid same
trouble. This is called “Yokoten” (means expansion to other).
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4. Implementation of LM

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 1) Stages of LM

Stage of LM is as follows. The most important is that

three stages finally wrapped and continue.

Stage.1 Performing “KAIZEN”

Stage.2 Establishing Continuous flow

Stage.3 Integration

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1-1) Stage.1 Performin“KAIZEN”

Stage.1 is the most important in all satges and

time-consuming stage.
When this stage takes hold, productivity can be
improved by at least 10~20%.

< Activities>

・Raising awareness of KAIZEN

・Promotion of 5S
（Sort, set in order, Shine, Standardize, Sustain)
・Understanding 3M
（Muri=Overburden, Muda=waste, Mura=unevenness)
・ Eliminating 7 wastes(Muda)
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1-2) Stage.2 Establishing Continuous Flow

Stage.2 is the stage of building the continuous flow of

each line while continuing to KAIZEN.
At this stage, detailed process data will be obtained to
improve line efficiency.
Ultimately, the goal is standardization.

＜Activity＞
・Process layout change
・Staffing by multi-skilled workers
・Review of production lots and changeovers
・Standardization of all processes and operations

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1-3) Stage.3 Integration

The main purpose of Stage.3 is to integrate whole

system.

The most important thing is to make the most of what

was established in Stage 1&2 to determine the activity
of Stage 3.

<Activities>
・“KANBAN” ＝Promotion board
・”Heijyunka” =Production leveling
・”jidouka” =Autonomation

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2) Tips for implementation of LM

1. LM is not an improvement on things. It is an

improvement of the mechanism.

2. First of all, what are you struggling with? Let it be a

chance to think.

3. Gather the ideas of 10 people rather than the

inspiration of 1 person.

4. Trial and error first. You don't need a 100% finished

drawing. Take action first.

5. If you get stuck, go back. Restart from 5S.

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Thank you for your attention.

I wish you success in this project starting next week.

See you in Pakistan !

Tametomo（Tom) Yamamoto

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