SEMINAR ON

LEAN
MANUFACTURING

Submitted by : MUDIT SAND

Contents :
o Introduction
o Lean tools
o Benefits of lean manufacturing
o Barriers to lean implementation
Introduction
Lean manufacturing is a systematic approach to
identifying and eliminating waste.
In 1940s the ratio of production between America
and Japanese workforce was nine to one In
practice of reducing this gap results into the birth
of Lean manufacturing.
It began as a description of procedure used by
the Toyota Motor Corporation from 1950 through
1980.
Toyota production system was successful in
eliminate waste, reducing operating expenses
while increase in production quality.
Waste
waste is anything (activities, processes, tools,
materials, personnel) that does not add value to
the product or service as viewed by the
customer.
Types of wastes:
Overproduction
Waiting
Transportation
Overprocessing
Movement
Inventory
Making defective parts
Lean Theory
Lean theory is a production practice which
intends to minimize waste along entire value
streams and create more value for customers.
According to lean, any utilization of resources
that does not ascribe value for the customer is an
objective for change or elimination.
Lean principles
Five key principles:
Identify value
Map the value stream
Create flow
Establish pull
Seek perfection
Lean Tools
Once enterprises pinpoint the major sources of
waste, lean tools will guide organizations through
corrective activities to eliminate waste and
continuous improvement.
Various lean tools are JIT, Takt
time,Kanban,Kaizen,5s,Heijunka,Jidoka,3Ms,PDCA
, Value stream mapping.
Just in time
It is a tool of lean manufacturing that stands on
the pillars of successful planning and the
execution of events necessary to produce a final
product.
each event and process should be processed in
the right form, in the right necessity to produce
goods and with the right timing.
Takt time
It is how fast you need to manufacture product in
order to fill your customer orders. Lean
Manufacturing Takt Time is calculated as:
Takt Time = Planned Production Time / Customer
Demand
Producing faster than takt time result
overproduction
Producing slower than takt time results
bottlenecks
Kanban
Kaizen
Kaizen, Japanese for "improvement" or "change
for the best", refers to philosophy or practices
that focus upon continuous improvement of
processes in manufacturing, engineering, and
business management
5S
Sorting
Straightening
Shining
Standardization
Sustain
Heijunka
Heijunka means sequencing, or smoothing of
production
The objective of Heijunka is to absorb sudden
fluctuations in market demand by producing
several different models in small batches on the
same line. It is the principle of one piece flow
The practice of Heijunka also allows mudas to be
eliminated by making it easier to standardize
work
Jidoka
3Ms
Muda
7 Wastes and waste of talent, Resources and By-products
Mura
waste of unevenness or inconsistency

Muri
Waste of overburden
PDCA
PDCA stands for Plan-do-check-act cycle
Plan: Identifying and analyzing the problem
Do: Developing and testing a potential solution
Check: Measuring how effective the test
solution was, and analyzing whether it could be
improved in any way
Act: Implementing the improved solution fully
Value stream mapping
Used for improving the flow of inventory and
information
Five principles
Benefits of Lean
Manufacturing
Reduction in cost
Improvements in quality and safety
Time reduction for traceability
Culture change
Reduction of fatigue and stress
Barriers to Lean
implementation
Resistance to change in working culture
Lack of commitment from management
Employees attitude
Lack of financial resources
Lack of time
Thank you