Lean Manufacturing Concepts and Tools and Quality Management

By Hristina Koycheva

What is Lean?
Lean is an Operational Excellence Strategy that enable you to change for the better- in fact the Japanese often use
Kaizen which use by lean practitioners to describe incremental improvements ;

What is Lean?
Persistent process in elimination of waste MUDA describes any activity thats

done, but add no real value to the product or service.

What is Lean?
Respect for people

High Quality and Stable Processes

Where?
At all level there is a strong desire to be better; A culture of lean is visibly prioritised and practice from the top to the bottom of the workforce; The key is understanding the customer and delivering his requirements;

How?
Improves business performance using simple practical tools and techniques to enhance quality, cost, delivery and people contribution; Exposes the wastes in the system; People need to change their long standing work practices and ideas; Senior management need to drive lean principles forward with total commitment to its success; Not a bolt on technique, more a way of life leading to a total change in culture.

Short History
1913: Henry Ford (Start of mass manufacturing with the moving line) 1938 JIT Born

Short History
1950: Eiji Toyoda brings the ideas of continuous moving line in Japan

Short History
1960: Toyota production System, main principles of lean manufacturing 1991: Lean Management

Main Principals
Identify the customer Map the flow Make a product or service flow Create polls based on customer demands Continually find ways to improve

Lean Tools
Assessment and planning-

fundamentals and understanding where we are today and creating and design for tomorrow.

Plan, Do, Check, Act

Lean Tools
5 S
Visual control Standardize work Total productive maintenance

Select the key

Select the

key

Reduce cost of production Increase customer satisfaction Improve quality

Map Process

Establish Customer Poll

Eliminate Waste

Make Process Flow

What Is Waste?
Waste of waste) Waste of Waste of Waste of Waste of Waste of Waste of overproduction (largest
time on hand (waiting) transportation processing itself stock at hand movement making defective products

Lean Thinking
Value

Key Principals of Lean Thinking

- what customers are willing to pay for; the steps are delivered value; Stream to be continuous;

Value Stream

Flow organizing Value

Polls responding to downstream customer demand; Perfection relentless continuous improvement

(culture);
Lean Thinking, Womack and Jones,1996

Conclusion
Lean is:
A

systematic approach to identifying and eliminating waste (non-value added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection.

Production System
Two pillars: Jidoka Just-in-time

What is Jidoka?
Jidoka means autonomous. The responsibility of each associate to deliver Quality to the customers. - Intense Motivation
Training; - Explained Information;

Just-in-time
Aims of zero inventory; Parts are not kept in warehouse; Parts arrive when needed;

Quality system
Quality means compliance with specifications- no less, no more; No need for inspections!

Quality Assurance
When we focused on this we will consistently deliver what the customer expects; Trust raises everyones commitment

Thank you!