CONTENTS:-

 History & Evolution

 Craft & Mass Manufacturing
 Origin of lean
 Definition of lean
 Lean manufacturing
 Types of wastes
 Lean tools
 Lean Principles
 House of lean
 Reference
 LEAN FAMILY TREE

LEAN
TOYOTA TOYOTA PRODUCT
PRODUCTION SYSTEM DEVELOPMENT SYSTEM

PRODUCT
MANUFACTURING
SUPPLY DEVELOPMENT
CHAIN

(virtual integration)
SOFTWARE
OPERATIONS
DEVELOPMENT
FEATURES OF LEAN MANUFACTURING

WHAT IT IS WHAT IT DOES

•Management philosophy •Attacks waste

• "doing things right" more than "doing • Exposes problems and bottlenecks
the right thing" • Achieves streamlined production

WHAT IT REQUIRES WHAT IT ASSUMES

•Employee participation
•Industrial engineering/basics
•Continuing improvement Stable environment
•Total quality control
•Small lot sizes
LEAN MANUFACTURING
• A way to eliminate waste and improve efficiency .
• Lean is focused at cutting “fat” from production activities.
• Successfully applied to administrative and engineering
activities as well.
• It is a Japanese method focused on 3M’s.
➢ Muda- the Japanese word for waste.
➢ Mura- the Japanese word for inconsistency.
➢ Muri- the Japanese word for unreasonableness.
Business as Usual

Product
Customer WASTE
Order Shipment

Time

Lean Manufacturing

Customer Product
Order Shipment

Time(Shorter)
 WASTE(MUDA) AND ITS TYPES
 Anything that happens to a product that does not add value from the
customer’s perspective is waste.
 TPS definition of waste:
➢ Overproduction
➢ Waiting, including time in queue
➢ Transportation (between workstations, or between supplier and
customer)
➢ Non-value-adding activities
➢ Inventory
➢ Waste motion
➢ Cost of poor quality: scrap, rework, and inspection
 LEAN TOOLS
TOOL INTRODUCTION BENEFITS

5S • Sort (eliminate that which is not Eliminates waste that results from
needed) a poorly organized work area (e.g.
• Set In Order (organize wasting time looking for a tool
remaining items)
• Shine (clean and inspect work
area)
• Standardize (write standards for
above)
• Sustain (regularly apply the
standards)

Value Stream Mapping A tool used to visually map the Exposes waste in the current
flow of production processes and provides a roadmap
for improvement through the
future state.
 TOOLS INTRODUCTION BENEFITS

• Minimizing Wait Times and

Logistics Costs
A system of continuous supply of
components, parts and supplies, such that • Reduce Stock Levels and
Kanban
workers have what they need, where they Overhead Costs
need it, when they need it
• Reduce Inventory Costs

A techniques that help operators avoid • Better safety

mistakes in their work caused by choosing
Poka-yoke • Reduce breakdown
the wrong part, leaving out a part, installing a
part backwards, etc. • Improve Productivity
• WIP and lot size reduction
The practice of reducing the time it takes to • Finished goods inventory
SMED (Set up
change a line or machine from running one reduction
reduction)
product to the next
• Improved equipment
utilization/yield
 TOOLS INTRODUCTION BENEFITS

• Stability of manpower
• Reduction of unnecessary
the leveling of production by both volume and overtime
Heijunka
product mix • Reduction in inventory levels
• Reduction of stress levels in
the production area
• Identify root cause
• Identify current and future
It is a method of questioning that leads to the needs for organizational
5Ws & 1 H
identification of the root cause(s) of a problem improvement.
• Develop a logical approach to
problem solving
Just-In-Time (JIT) Pull parts through production based on • Highly effective in reducing
customer demand instead of pushing parts inventory levels.
through production based on projected • Improves cash flow and
demand. reduces space requirements