Principles and Practices of

Lean Manufacturing

By Saurabh Gour

CONTENTS
What is Lean ?
The Lean House
Principles of Lean
Goals of Lean
The 3Ms
Major Wastes (TIMWOODS)
Tools and Techniques of Lean
Practical Implementation

WHAT IS LEAN ??
Lean is a systematic approach for identifying and eliminating waste (non-

value-added activities) through continuous improvement.

Improved flow = Decreased cost

Decreased cost = Sustainable profits

The Lean House

QUALITY
(Customer satisfaction to earn profit)

DELIVERY TIMES

COSTS

JIT

JIDOKA

(The seven zeros for zero inventories)

PILLER-I

(Stop & notify anomalies)

TAKT
(Pace ofTIME
production to meet

MAN/MACHIN
E
SEPARATION
(Multimachine capabilities)

demand)

PULL FLOW

PILLER-II

(Smaller batches, quick

response to customer demand
and smooth product flow)

HEIJUNKA

STANDARD WORKING

(Production leveling)

REDUCTION IN
MUDAS

KAIZEN

(Reduction in all wastages)

(Continuous improvements)

STABILITY

(Team stability, method standardization, strategy monitored over time)

Principles of Lean
Define value from customer perspective
Specify value from the standpoint of the end customer by product
family.

Identify the value stream

Identify all the steps in the value stream for each product family,
eliminate those steps that do not create value.

Make the process flow

Make the value-creating steps occur in tight sequence.

Pull from the customer

As flow is introduced, let customers pull value from the next
upstream activity.

Head towards perfection

Begin the process again and continue it until a state of perfection is
reached.

Goals of Lean
Improve
Quality
To minimize
cost,
company
must
produce
customer
demand
only.

Reduce
Total
Cost

Reducing the time it takes

to finish an activity from
start to finish is one of the
most effective ways.

LEAN
GOALS

Reduce
Time

Company must understand

what customer wants & needs
to meet his expectations and
requirements.

Eliminate
Waste

Waste is any
activity that
consumes
time, resource
or space but
does not add
any value to
the product or
service.

3M's: Mura, Muri and Muda

MURA (Unevenness)
Any variation leading to
unbalanced situations

3 Ms
MURI (Overburden)
Any activity asking stress
or effort from personnel,
material or equipment.

MUDA (Waste)
Any activity in process
that does not add value.

The Major Wastes (TIMWOODS)

Transportation

Any movement of material that is not required for justin-time production.

Inventory

Any supply in excess of one piece flow.

Motion

Any movement that does not add value.

Waiting

Being idle between operations.

Over-Production

Producing more or sooner or faster than needed.

Over-Processing

Effort which add no additional customer value to part.

Defects

Rework of products to fulfill customer requirements.

The new waste is introduced recently. So, there are total 8 major wastes of
lean manufacturing in the useful mnemonic TIMWOODS.

Skills
(Unutilized human brains)

Due to not engaging employees, listening to their ideas.

Tools and Techniques of Lean

5s Visual Workplace
Poka-yoke (Error Proofing)
Kanban
Kaizen
Cellular Manufacturing
SMED
OEE
Just-in-time (JIT)
Jidoka

5-S Implementation
5S activity seeks to organize the work place in a way that makes it more

productive.
SEIRI

Remove what
is not needed

(Clear/sort)

Develop an
attitude to follow
above the 4S

SHITSUKE

SEITON

(Discipline)

(Set in order)

Standardize the
best practices &
process of
cleaning

SEIKETSU

SEISO

(Sustain)

(Shine)

Place things in
such a way that
they are easily
accessible

Keep things
clean & polished

The unorganized life without 5s

The systematic life with 5s

Poka-yoke (Error Proofing)

Contains fool proofs operations and reduces/eliminates mistakes in

processes.
Helps in minimizing defects before they reach the customer.
Investigation in the defect cause is essential to elimination.
Ex- Color-coding separation, provide fix stoppers.

Kanban
Card system that helps control flow & help to establish JIT goals.
Easy to understand and requires a relatively simple setup.
Card should be attached to a product container and contain essential

information (job card and job route card)

Kaizen
Kaizen means gradual and orderly, continuous improvement.
People work together to make improvements with low capital investments.
Benefits include: Simulation of workers, Save money & time, Create

belongingness.

Cellular Manufacturing
Work cells are central to the idea of one piece flow.
Equipment is movable and placed in close proximity.
Quick feedback between operators.
Benefits include: Higher throughput, Improved Co-ordination, Improvement

in quality and productivity.

SMED
Single Minute Exchange of Dies is a Process focused on reducing setup

time.
The main objective of SMED is Make operator as a surgeon.
Primary goal is to change all internal setups to external ones.
Reduce length of internal setup if unable to convert to external. Reduce

length of all external setups as well.

Benefits include: Lower manufacturing cost, smaller lot sizes, lower

inventory levels, smoother startups.

OEE
Overall Equipment Effectiveness is a measure of the how well lines or

equipment are utilized in relation to their full potential.

OEE = Availability x Performance x Quality
Set-up loss

Inconsistent times, Insufficient skills,

Different methods, Poor tooling

Breakdown
loss

Lack of maintenance, Low operator

interest, unawareness of problems

Minor Stoppages loss

Material not available, Change over at

start/ end Jams/ overloads

Speed loss

Unclear design specs, Incorrect

settings, Poor maintenance history,

Start-up loss

Poor machine changeover, Inconsistent

materials, No start-up check lists

In process
loss

Inconsistent materials, Process not

followed, Gauges not calibrated

Availability
(Measures Down Time Loss)

OEE

Performance
(Measures Speed Loss)

Quality
(Measures Quality Loss)

Just-In-Time (JIT)
Establish flow processes so there is an even, balanced flow throughout the entire production process.
Goal: Generate zero queues & Minimize lot sizes.
Benefits include: Reduced inventory levels (improved profits), Improved product quality, Reduced delivery lead times.

It is the ability for machines to be self-dependent and error proof without any human interaction.
It contains three elements :

o Separate human from machine work

o Machines detect/prevent abnormalities
o Stop the Line authority in operation

Jidoka

Practical Implementations in Current Project

OEE: Redesign floor layout and achieved 10% improvement in the overall
productivity by reducing maximum losses.

SMED: Making operator as a surgeon I have achieved quick changeover

in setups at press & CNC Shop.

Single Piece Flow: Reduce Manufacturing lead time 20% by the

elimination of batching concept.

Cell Concept: Establish cell layout for the manufacturing of flexible

jumpers, containing four lines.

Process Redesign: Reduce the production time and eliminate the

unnecessary processes using Time & Motion study.

Thank You