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 that’s 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.

delivery and people contribution.  Not a “bolt on” technique.How?  Improves business performance using simple practical tools and techniques to enhance quality.  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. .  Exposes the wastes in the system. more a way of life leading to a total change in culture. cost.

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     .

Do. Act .Lean Tools  Assessment and planning- fundamentals and understanding where we are today and creating and design for tomorrow. Check.  Plan.

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 .

– the steps are delivered value.  Perfection – relentless continuous improvement (culture). Womack and Jones. Lean Thinking.Lean Thinking  Value Key Principals of Lean Thinking .  Value Stream  Flow – organizing Value  Polls – responding to downstream customer demand.what customers are willing to pay for. Stream to be continuous.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. .Explained Information. The responsibility of each associate to deliver Quality to the customers. .Intense Motivation Training.

.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 need for inspections! . no more.

 Trust raises everyone’s commitment .Quality Assurance  When we focused on this we will consistently deliver what the customer expects.


Thank you! .