Lean Manufacturing

Definition
Lean manufacturing is the implementation of the
concept that anything that does not create value in
the product is to be eliminated. It is the concept of
more value for less work.
In simple words : Lean is a system of cost reduction
focusing on the elimination of waste .
OR
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.

TWO PILLER
It is built upon two pillars:
JIT and
Jidoka

JIT :- Just in time

Jidoka :- The term jidoka used in the TPS (Toyota
Production System) can be defined as "automation
with a human touch."
The Toyota term "jido" is applied to a machine with a built-in
device for making judgments, whereas the regular Japanese
term "jido" (automation) is simply applied to a machine that
moves on its own. Jidoka refers to "automation with a human
touch," as opposed to a machine that simply moves under
the monitoring and supervision of an operator.

JIDOKA

One principle of Jidoka is that no defective parts

should advance in the production system.
In a simple word; when we do have a defect, we
will need to shut down the line until the problem is
solved and were assured no defective product can
go forward

Need Cultural Change

Cultural Change Sometimes Seems Impossible
Ex. Shutting down line for each defective prod.
Example of two-month-old son to play soccer
First, he must crawl, then he must walk, then when he is
into running, there is some hope of teaching him soccer
before that, it is not a reasonable goal

Like the same way, The production plant must first

learn to crawlit must have a product to sell, must
have good leadership, good problem solvers, and a
willingness to change. Only then can it walk and
develop a solid quality system with high levels of
product stability, good process stability, and a deep
understanding of variation.

The Goals of Lean

Manufacturing
Cost Reduction by Elimination of Waste
Creating Conditions to Guarantee Product
Quality
Creating a Work Site with Operators in
Mind

Cost Reduction by Elimination of

Waste
A functional classification of the various elements
that only raise cost in production activity gives
the following seven types of waste:

Waste
Waste
Waste
Waste
Waste
Waste
Waste

of defect repair
of overproduction
of waiting
in delivery and conveyance
in processing
of inventory
of motion