LEAN

MANUFACTURING

DESIGNED BY:-SUNIT MAHAPATRA

BRANCH:-MECHANICAL
COLLEGE OF ENGINEERING
ENGINEERING, BBSR REGD. NO.:-1001219499
AGENDA
 DEFINITION
 ORIGIN
 KEY LEAN TECHNIQUES
 ADVANTAGES & DISADVANTAGES
 PEOPLE & CUSTOMERS
 ECONOMICS
 TOOLS FOR LEAN MANUFACTURING
 CONCLUSION
DEFINITION
 Lean Manufacturing – A way to eliminate waste and
improve efficiency in a manufacturing environment .
 Lean focuses on flow, the value stream and eliminating
muda, the Japanese word for waste.
 Lean manufacturing is the production of goods using less
of everything compared to traditional mass production:
less waste, human effort, manufacturing space,
investment in tools, inventory, and engineering time to
develop a new product.
WHAT IS WASTE?
 Waste is anything that

happens to a product that

does not add value from the
customer’s perspective.
 Products being stored,
inspected or delayed,
products waiting in queues,
and defective products do
not add value.
SEVEN WASTES
 Overproduction – producing more than the customer
orders or producing early. Inventory of any kind is
usually waste.
 Queues – idle time, storage, and waiting are wastes
 Transportation – moving material between plants,
between work centers, and handling more than once is
waste
 Inventory – unnecessary raw material, work-in-process
(WIP), finished goods, and excess operating supplies
 Motion – movement of equipment or people
 Over processing – work performed on product that adds
no value
 Defective product – returns, warranty claims, rework and
scrap
ORIGINS
 Lean Manufacturing is
sometimes called the ‘Toyota
Production System (TPS)’
because Toyota Motor
Company’s ‘Eiji Toyoda’ and
‘Taiichui Ohno’ are given
credit for its approach and
innovations.
KEY LEAN MANUFACTURING
TECHNIQUES
o 5S

o SINGLE MINUTE EXCHANGE OF DIES

o KANBAN

o CELLULAR MANUFACTURING
5S
 Strategy for creating a well organized, smoothly flow in
manufacturing process.
 It is a list of 5 “Japanese” words like: ‘seiri’ , ‘seiton’ ,
‘seiso’ , ‘seiketsu’ , and ‘shitsuke’ .
 This is all total how to organize a work space for
efficiency and effectiveness.
SEIRI:-
o The English meaning of this word is “sorting”.
o It includes to eliminate all necessary tools, pars .
o Go through all tools, materials in the work area and
keep only essential items and eliminate what is not
required.

SEITON:-
 It is otherwise known as “set in order”.
 Arrange the work, workers, equipments, parts, and
instructions in such a way that the work flows free of
waste through the value added tasks to meet the
demand.
SEISO:-
 This means “shine” in English.
 Clean the workspace and all equipments ,and keep it
tidy and organized.
 Everything should be restored and can be easily used for
the next user.
SEIKETSU:-
 This means “standardization”.
 Ensure uniform procedures and set ups throughout the
operation to promote interchangeability.
SHITSUKE:-
 This means “sustain”.
 To keep all above as per rules & procedures.
BENEFITS OF 5S
 Increases organization and efficiency
 Avoids wasted motion

 Increases safety

 Eliminates unnecessary inventory

 Offers improvements at an inexpensive cost

 Identify problems more quickly

 Increase product & process quality

5S DRAWBACKS
 If not fully implemented, may result in “Jive S”
◦ Store things
◦ Stick to the rules
◦ Superficially clean
◦ Switch to new fixtures
◦ Serve reluctantly

 Can not be considered an end goal – must be part of a

continuous improvement movement
SINGLE MINUTE EXCHANGE OF DIES
(SMED)
 Method that focuses on the rapid conversion from
manufacturing one product to the next
 It provides a rapid and efficient way of converting a
manufacturing process from running the current products
to running the next product.
 The “single minute” means all changeovers and start
ups should take less than 10 minutes or single-digit
minute.
BENEFITS OF SMED
 Increases throughput by reducing setup times
 Eliminates setup errors

 Increases safety

 Reduces the cost of setups

 Reduces waiting times and inventory buildups

 Decreases the required skill level of the operators

KANBAN
 A system that uses renewal signals to simplify inventory
management
 Signals (usually cards) hold product details
 What to make, when to make it, how much to make, and where to
send it
 Cards stay attached to a bin that holds the product
 When bin is empty, it is returned to the start of the assembly
line for replenishment
 Full bins are returned to the customer, and the cycle continues
BENEFITS OF KANBAN
 Highly visible systems
 Simple, effective, and inexpensive

 Reduces inventory and eliminates stock-outs

 Improves the quality of service

 Improves lead times

CELLULAR MANUFACTURING
 Dividing the manufacture of products into semi-
autonomous and multi-skilled teams known as work
cells
BENEFITS OF CELLULAR
MANUFACTURING
 Simplifies material flow and management
 Reduces interdepartmental travel

 Reduces throughput time

 Reduces lot sizes

 Simplifies scheduling
LEAN MANUFACTURING
ADVANTAGES AND DISADVANTAGES
 Advantages:  Disadvantages:
 Increased overall
productivity
 Reduced amount of floor
space required
 Reduced manufacturing
lead time
 Improved flexibility to
react to changes
 Improved quality
 Difficultyinvolved with
changing processes to
implement lean principals
 Long term commitment
required
 Very risky process - expect
supply chain issues while
changing over to lean
HOW PEOPLE BENEFIT FROM LEAN
Element Traditional Lean Improvement

Communication Slow & Uncertain Fast & Positive Quality &

Coordination

Teamwork Inhibited Enhanced Effective Teams

Motivation Negative, Extrinsic Positive, Intrinsic Strong Motivation

Skill Range Narrow Broad Job Enrichment

Supervision Difficult and Easy & Localized Fewer Supervisors

Fragmented
HOW CUSTOMER’S BENEFIT FROM LEAN
Element Traditional Lean Improvement

Response Weeks Hours 70-90%

Customization Difficult Easy Competitive

Advantage

Delivery Speed Weeks-Months Days 70-90%

Delivery Reliability Erratic Consistent & High Up to 90%

Delivery Quantities Large Shipments JIT as Required Locks in JIT

Customers

Quality Erratic Consistent & High Delighted

Customers
ECONOMICS
 Reduction of Inventory
 Less space necessary to hold inventory
 Reduced Waste
 Decreased Production Cost
 Increased market share
 Able to provide what the customer wants quickly
 Increased competitive advantage
 Faster response to the customer
 Lower Cost
 Higher Quality
CONCLUSION
 Lean, as a concept or brand, has captured the
imagination of many in different spheres of activity.
 Lean’s waste reduction practices, a company reduced
handle time, agent variability, and attained near perfect
process adherence.
 Lean practitioners may easily focus on the tools and
methodologies and fail to focus on the philosophy and
culture of lean.
 In lean manufacturing , it is very necessary to avoid
failed implementations.
 S ?
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