Lean Manufacturing

Nicholas Kirsch, Mohammed Ahmed, Lindsay Flynn, Tara Hillriegel, Catie Gould Hillriegel,

Agenda
      

Definition Timeline Techniques Pros & Cons Demonstration Case Studies Conclusion

What Is Lean Manufacturing?

An overall strategy to improve a production process that focuses on:
Eliminating wastes Enhancing quality Reducing production time and cost Promoting a lean culture in the company

Goal Of Lean


Reduce:
Human effort Inventory Time Space Cost

EFFICIENCY

What does waste mean?

      

Rework Overproduction Conveyance Waiting Inventory Motion Over processing

History of Lean Manufacturing

Dr. W Edwards Deming



Worked in Japan after WWII on quality methods and techniques Wrote System of Profound Knowledge His 14 points of management towards improving quality through lean manufacturing Seven deadly diseases or Seven Wastes

Toyota Production System

Find the correct process to produce desired results

Develop workers and partners to add value to the company

Solving root problems

Muda, Muri, Muda, Muri, and Mura

Muda wasteful or

unproductive activity
 

Mura - unevenness Muri overburden,

unreasonableness

Pull Production
 

Minimum Inventory Supplying the right part, at the right time, in the right amount

Each sub-process draws its needs from the subpreceding sub-processes, and ultimately from an suboutside supplier.

When a preceding process does not receive a request or withdrawal it does not make more parts.

Autonomation
Intelligent Automation:
1. 2. 3.

4.

Detect the abnormality. Stop. Fix or correct the immediate condition. Investigate the root cause and install a countermeasure.

Fixed Repeating Schedules

Red Stream/Green Stream
Green Stream: Continuously produces products for which there is a stable demand Red Stream: Flexible work schedules and factory layouts allow products to be produced only when ordered


Shortening FRS
Reduces amount of stock needed


Improves efficiency of sub processes

Leads to lower lot sizes and enhanced flexibility

Kaizen (Continuous Improvement)

     

Identify a problem Collect input from employees Make a change Monitor results Adjust Apply across the board

Lean Manufacturing Pros

 

Minimizes the overhead fixed cost; reduces operational cost Implementing manufacturing techniques and strategies reduce manufacturing time

Targets to eliminate most of the wastes that were mentioned on the previous slides

 

Use of energy will be significantly reduced Tries to eliminate wasted space since it is very important for the company to run smoothly

Lean Manufacturing Cons



Support of employees and upper management throughout the overall org chart is necessary to make the lean techniques implement in the company and make them successful. Proper leaders should be trained to direct teams about lean manufacturing and how it works. Leaders should be employee friendly since there can be personality clashes and it is difficult to get people to follow and take orders from co-workers. coTraining is an on-going process and it is a long time onprocess to completely adopt lean manufacturing for the overall company.

Demonstration

Case Studies - Boeing Manufacturing Business UnitUnitIssues

  

Average job moved to 30 different stations Pieces travelled miles throughout the shop Most space was used for storage of work in progress

Large inventory

Changes and Results

   

Product based cells Wheels on equipment for flexibility Storage spaces stocked to max/min Overall travel was reduced between 1 and 3 miles Reduced need for forklifts and trucks

Changes and Results

   

Reductions of bulk purchasing Manufacturing occurs in ship sets Just-inJust-in-time scheduling 100,000 square feet of storage space reduced OffOff-site storage no loner needed

Overall results
   

Reduced total cost of 30% Productivity improved by 39% Defects reduced from 12% to 3% Production flexibility increased 40-50% 40-

ZAK, Inc.

Conclusion
Lean Manufacturing is


A collection of philosophies and techniques that reduce waste and add value Becoming more accepted and implemented in industry Essential for a company to remain competitive in the long term

Questions?