LEAN MANUFACTUING-CONCEPT, LIMITATION, APPLICATIONS: AN OVERVIEW Submitted By Ms. PUNAM NIVRUTTI PATIL DPGD/OC13/1243 SPECIALIZATION: OPERATIONS WELINGKAR INSTITUTE OF MANAGEMENT DEVELOPMENT & RESEACH AUGUST 2015
INTRODUCTION Lean manufacturing- A way to eliminate waste & improve efficiency in manufacturing environment. Lean was generated from just in time(jit) Philosophy of continuous & forced problem solving. Lean is the fundamental way that many of the world s best companies do business. It is the production of goods using less everything compared to traditional mass production.
FORMS OF WASTE Muda- Any form of waste in process Muri- Unreasonable burden on people or machines Mura- Waste created through unevenness
GOALS Improve Quality Reduce total costs Reduce Time Zero accidents Zero inventory
LEAN MANUFACTURING PROCESS Identify waste Analyze the waste & find the root cause Solve the root cause & repeat the cycle
TOOLS 5 S Andon Bottleneck Analysis Continuous flow Gemba Heijunka Hoshin kanri Jidoka Just In Time kaizen Kanban Key performance indicator Overall equipment effectiveness PDCA Poka Yoke Root cause analysis SMED Takt time Total productive maintenance Value stream mapping Visual factory
Some of important tools 5 S Clearing (Seiri) 2. Organizing (Seiton) 3. Cleaning ( Seiso) 4. Standardization (Seiketsu) 5. Discipline & Training (Shitsuke) Just In Time The ideal just in time facility would carry zero finished goods and build them only when they are ordered kaizen Kaizen simply means "change for better The Toyota Production System is known for kaizen
KANBAN The basic concept of a kanban is a hand sized card that moves with the product or material. There are two basic classifications of kanbans; generic and brand. Within the two classifications there are two main types of kanbans; production kanbans and move kanbans Total Productive Maintenance TPM (Total Productive Maintenance) is a holistic approach to equipment maintenance that strives to achieve perfect production: No Breakdowns No Small Stops or Slow Running No Defects In addition it values a safe working environment: No Accidents
KEY IMPLICATIONS OF LEAN MANUFACURING Traditional Batch Manufacturing Lean Manufacturing Orientation Supply driven Customer driven Planning Inventory Handoff of work in process Orders as pushed through factory based on production plan / forecast Buffer of work in progress between each production stage Material after each stage accumulate into work in progress stage areas before being retrieved by next production stage Production cycle time Longer than actual time Shorter Orders are pulled through factory based on customer / downstream demand Little or no wok in progress between each production stage Material handed of directly from one production stage to next
Supply Problems High cost of implementation Lack of acceptance by employees Customer dissatisfaction problems New inefficiencies Problems in Just In Time (JIT) Worker frustration Over focus on waste Over focus on present Lack of standard methodology LIMITATIONS
APPLICATIONS In process industries In financial service sector In emergency department In construction industries In pharmaceutical industries In public
Toyota Production System TPS has three desired outcomes: To provide the customer with the highest quality vehicles, at lowest possible cost, in a timely manner with the shortest possible lead times. To provide members with work satisfaction, job security and fair treatment. It gives the company flexibility to respond to the market, achieve profit through cost reduction activities and long-term prosperity.
CONCLUSION Lean manufacturing 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.