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BE.

Mechanical Engineering

LEAN MANUFACTURING

MECHANICAL ENGINEERING

LEAN MANUFACTURING SYSTEM 1. Lean manufacturing is a production strategy that aims at high level of production using lesser effort, time and materials. 2. It is an integrate business approach adopted to eliminate the non -value added activities from the customer delivery cycle in the operations. 3. This approach enables the companies to respond quickly and profitability to changes in customer demands. It is not only restricted to shop floor. 4. The techniques of lean manufacturing can be applies t o every situation in a company by finding out what the customer wants, eliminate waste from processes and making flow continuously according to customer pull. 5. The idea is to create cultures in which people at various levels of an organization continuously improving their productivity everyday in every way. 6. Lean manufacturing process optimum result only, if it is implemented as an ongoing improvement process involving everyone at each level. 7. The four pillars of lean manufacturing are a. JIT concept, b. Supply chain integration, c. Cellular manufacturing and d. Kaizen.

LEAN MANUFACTURING

Vaibhav V Naik

MECHANICAL ENGINEERING

The four pillars of lean manufacturing are shown in the figure.

Figure: Pillars of Lean Manufacturing

Special feature of lean Manufacturing 1. Lean manufacturing produced goods with few people, little inventory and little wastes. 2. Lean ensures that each production stage processes exactly what, how much and exactly when next stage wants it. 3. Leans allow large variety in products without the kind of changeover costs the customized mass manufacturing involves. 4. Leans embrace every facts of the organization, sourcing, manufacturing, marketing accounting and strategic planning.

LEAN MANUFACTURING

Vaibhav V Naik

MECHANICAL ENGINEERING

Figure: Lean Manufacturing Process

LEAN MANUFACTURING

Vaibhav V Naik

MECHANICAL ENGINEERING

ADVANTAGES AND LIMITATIONS. 1. Inventory levels are very low because of use JIT. 2. Simple and multitasks machinery which aids variety products manufacturing. 3. More values to the customer. 4. Reduction in manufacturing lead time. 5. Integrates people and techniques to improve the work place and Strengths Companys competitive position.

Difficulty in adopting Lean technique 1. Shortage of resources that can inhibit the reengineering of process. 2. A smooth flow is required throughout the supply chain 3. Natural calamities affect the efficiency of logistics. 4. Training and know how at each level of organization.

This concept demands a fundamental change in corporate culture. There is need for understanding, co-operation, and teamwork between management and by the workforce. It aims continuously improving efficiency and profitability of the company by attacking all kinds of wastes from operations and attacking the problem right away including the environment issues.

LEAN MANUFACTURING

Vaibhav V Naik

MECHANICAL ENGINEERING

Comparison between Traditional and Lean Manufacturing

Sr .No

Parameter

Traditional manufacturing

Lean Manufacturing

1 2

Production Manufacturing lead time

Made to stock Low

JIT Short

Both quantity

Large

Small

Scheduling

Push

Pull

Inspection

Sampling

100% at source

Layout

Activity based

Cellular type

Inventory twins

Low

High

Flexibility

Low

High

People Empowerment

Low

High

LEAN MANUFACTURING

Vaibhav V Naik