LEAN X MANUFACTURING

Lean also called

manufacturing as

Lean Production is a set of tools

and methods that aim for the
continuous elimination of all waste
in the production process The main

benefits of this are lower production

cost increased output and Shorter
production lead time
Lean production is an approach to

identify eliminate
and waste and
Non value added NVA
Activity
through continuous improvement and
customer value
increasing
Lean comes from the ability to
achieve more with less resource by
the continuous elimination of
waste
 Lean aims at
Manufacturing improving
systems and practices to deliver
more and better value with lesser

inputs It considers of resources

use

for any goal other than creation of

value for customer as undesirable
and to be wasteful and therefore
it should be eliminated

Five principles of Lean

1
Value Determine
and specify
what adds value to the customer
and what does not Customer needs
a
good quality good prices and
with fast speed Quality of the
delivery
product should meet the customers
expectation Non values added CNVA
process are those which customers
not to Pay These
are
willing
NVA add cost to the product and
delay manufacturing process
2 V m This involves
every
step of the process starting from
the and
supplier ending with the
customer
Every step must
bring
the product closer to the completion
and add value to it

3 Make the product flow All the

obstacles that are
constraining
the flow of the parts through
the must
manufacturing processes
be removed Lean strive for one
piece flow which is about providing
smooth flow for each piece of product
with no waste in time performance
and quality in order to deliver
the product to the customer
quickly
4 Pull not Push what
producing
the customer needs and avoid over

production Product should be only

produced when there is demand
from the customer side
5 Strive for perfection There must be
a vision for
perfection Companies
should continously try to improve the
process rather than being good at
what they are
doing
n Lean Production

The seven wastes are those non value

added NVA steps or process that
reduces the flow of stream add
cost to the product reduce quality
the
and delay process

Central Theme of Lean

Muda Non value added

Activities waste
waiting
Mura Inconsistent Irregular
or uneven use of person or

machine
Muri physical strain and
overburden
 30 tons of Iron
Safe capacity per Truck is 15 Ton load

Muda 3 truck have 107M each

waste

Maya 2 truck one with 207cm

uneven other 10 Ton

Mauri one truck carrying all

overburden
30 Ton load

No Muda Meera Mari

2 Truck with
each of 15 Ton load

Mari and Mura lead to Muda

 Mudas
original seven
wastage
In Short TIM WOOD

1
Transportation
2
Inventory
3 Motion
4
waiting
5
Overproduction Excess production
6 over
processing
7 Defects

Later on an 8th waste is added i e

underutilized people Non utilized

skill or Talent

Now defined as DOW NTIME

D Defect
0 over
processing
w
waiting
N Non utilized Talent
7 Transportation
I
Inventory
M Motion
 E Excess Production

L Transportation
Main factors for better efficiency
1 Layout of plant
2 Distance between the different
manufacturing process steps
3 Distance between machines
inside each workstation
4 How close are the workstations
and machines to the tools
5 How far are the
inventory
warehouses from the production
facilities
6 How far are the other Service
the maintenance
departments such as

workshops from the production line

 2 use a IT
Inventory
Should be
ITR high
points for cost effective Inventory
1 Return on Investment Roz
2 Risk should be less FMCG
3 Material
handling
4 Space
5 Insurance and taxes

is
3
Metron This
ergonomics The

operator needs to have his tools

and parts handed to him in

exactly the right orientation to

eliminate wasted and
walking
losses
handling SS

4 This is the time waste

Waiting
factor and it involves the
activities
following for materials
a
waiting
b for parts
Waiting spare
 b Wal for S are parts
ing
c for
waiting quality inspection
process
d for services such
waiting as

for crafts
waiting for maintenance
e
waiting quality inspectors
f Low machine
performance speed
machine downtime Breakdown
g
repairs and preventive
maint nance
h for operators to get
waiting
tools or spare parts
i
waiting for
changeovers from
to another
one
product

5 over production Related to Inventory

than what
Making product more

is actually needed or over the

capacity of department is
selling
a waste of and time
money

The aim is to make only what is

needed and when needed A method
like Kamban can be used to produce
to the customer's demand
according
 Cor l us ma
ng

Advantage of pull system

1 Problems are Surfaced quickly
to customer
2
produce according the
needs Saving cost resources
3 Reduce WIP Inventory
4 Shorter lead time
5 Increase value added work
6 Better quality control

6 over It
processing means
making
what
more
steps in the process than
are
actually needed or
making
steps that are not needed
Ask
questions Improve

7
Deeds

8
underutilized Talent
 Lean
Key Manufacturing
Techniques or pillars to
achieve Lean
Manufacturing
1 555
2 T IT
3 Kaizer
cellular
A
technology

I 55

sort Remove
things that you do
not need

Set in order
Arrange essential items
in such a
way that it is
easy to access them

shine stations tools

Keep working
machines clean and
keep the order
 machi es clean and
keep the order
set No trash and dirt

Standardize Establish rules

checklists standards
and procedures to keep
clean and in order
everything
Sustain Convert SS into a habit
visual
Use
language and
signboard to sustain the habits

Z JIT Kamban
already
covered

3 for
Karin means
change
better
or continuous Improvement
It is a
Japanese business
philosphy regarding Continously
improve operations and involve all
employees
1 Continous small improvements
2
Changes are
implemented quickly
 Chang are
mpeme ed que Kly
3
Everyone gets involved

4 Cellular
Technology
Manufacturing cells are designed
to process parts of the product in
separate fixed areas thus eliminating
non value added activities
production workstations and
equipments are arranged in a

product aligned sequence such that

layout creates
ultimately the a

single piece flow layout

This
increases production velocity and
flexibility
It decreases the order flow time
WIP material costs and
thus
handling satisfaction
customer
increasing