m




Ehsan Hameed
BET-FA07-033
A systematic approach to identifying and
eliminating waste through continuous
improvement by flowing the product at the
demand of the customerµ. Lean is about doing
more with less: Time, inventory, space, people,
and money. Apparel manufacturers- pressed to
deliver high quality garments at low costs.
V After the Second World War, Japanese industry
underwent complete rebuilding

V Manufacturers did not have the volume to

justify Detroit-type mass production assembly
lines, and needed a better way

V Lean production principles were developed by

Japanese engineers based on practical
considerations, and are largely a matter of
common sense
 JIT (Just In Time).

2 5s.

3 Total productive maintenance.

4 QFD (Quality Function Deployment)

5 Kanban tooling
V Äses a systems approach to develop and
operate a manufacturing system

V Organizes the production process so that parts

are available when they are needed.

V A method for optimizing processes that

involves continual reduction of waste
V Total Quality Management

V Production Management

V Supplier Management

V Inventory Management

V Human Resource Management

V Materials Cost Savings

V Manufacturing Cost Savings

V Sales Cost Savings

Creates a clean, ordered and disciplined work
environment.
Sort ² (Seiri)

The first 
focuses on eliminating unnecessary items from the
workplace.
 Set in Order ² (Seiton
Seiton))

] Painting floors
] Outlining work areas and
locations
] Shadow boards
] Modular shelving and cabinets

[ m

 


  



   m


Shine ² (Seiso)
Seiso)
Once you have eliminated the clutter and junk that has been clogging your
work areas and identified and located the necessary items, the next step is to
thoroughly clean the work area. Daily follow-up cleaning is necessary in
order to sustain this improvement.
Standardize ² (Seiketsu)
Seiketsu)
Standardize means establishing ´Best Manufacturing,

] Workplace Layout and Design

] Materials Handling Analysis
] Clear and Concise Work Instructions
] Well Defined Work Methods
] Safe (Ergonomic) Working Practices
] Cycle Time Reduction
] Training
] Documentation
Sustain ² (Seiketsu)
Seiketsu)

This is by far the most difficult  to implement and achieve.

Human nature is to resist change and more than a few

organizations have found themselves with a dirty cluttered shop
a few months following their attempt to implement 5S.
V It is a foundation for Lean
Reduces waste

Ö Less searching

Ö Decreased walking and motion

Ö Reduced downtime

Ö Fewer accidents

Ö Fewer mistakes

Ö Improved flow

Ö Better use of space

V µ Ineffective equipment is a form of waste

V TPM seeks to find the root causes of equipment

problems, and fix them

V Done using continuous improvement methods

V Preventive maintenance done by operators
V Restore and redesign equipment to make it
á


 and to extend its life
V Eliminate human error in maintenance and
operation
Education and training

Improved maintenance procedures

þ
  
 

 


 
 
V þ 

§ Meeting the specifications

V p 

§ Function that forms quality

V r   
§ Step-by-step deployment of that

function
V Customer Driven

V Reduces Implementation Time

V Promotes Teamwork

V Provides Documentation
V =





s
V =
  


V A Kan-ban is a card containing all the
information required to be done on a product at
each stage along its path to completion and which
parts are needed at subsequent processes.
V These cards are used to control work-in-progress
production, and inventory flow. A Kan-ban
System allows a company to use Just-In-Time
Production and Ordering Systems that allow them
to minimize their inventories while still satisfying
customer demands.
i
2. m 
3.
!"#$$%- used when shortages of parts
occur
4.
&#'# (%- used to replace defective
parts and other uncertainties such as machine
failures or changes in production volumes
5. '%- used when adjacent work
centers are located close to each other. It combines
production and withdrawal kan-bans for both
stages onto one, through, kan-ban
V 222
 



 

V 222   

 !"

V 222 

! 

 
 þ 

#$%p


#$%r   


V 

á    á