6366849 Lean Production

7/24/2019 6366849 Lean Production

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LEAN PRODUCTION

Prof. Kaushik PaulAssociate ProfessorOperations AreaE-Mail: [email protected]: 43553!"
mailto:[email protected]:[email protected]


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Lean Production Defined

The Toyota Production System

Lean Implementation Reuirements

Lean Ser!ices

O"#ECTI$ES


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LEAN PRODUCTION

Lean Production can %e defined as an inte&rated setof acti!ities desi&ned to achie!e hi&h'!olumeproduction usin& minimal in!entories (ra) materials*

)or+ in process* and finished &oods,

Lean Productionalso in!ol!es the elimination of)aste in production effort

Lean Productionalso in!ol!es the timin& ofproduction resources (i-e-* parts arri!e at the ne.t)or+station /0ust in time1,


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P#$$ %&%'EM

Customers

Sub

Sub

Fab

Fab

Fab

Fab

Vendor

Vendor

Vendor

Vendor

Final

Assembly

Here the customer starts

the process, pulling an

inventory item from

Final Assembly

Then sub-

assembly work is

pulled forward by

that demand

The process continues

throughout the entire

production process and

supply chain


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2EATURES O2 LEAN PRODUCTION

Management philosophy Pull system though the plant

WHAT IT IS

Employee participation Industrial engineering/asics !ontinuing impro"ement Total #uality control Small lot si$es

WHAT IT %E&'I%ES

Attac(s )aste E*poses prolems and ottlenec(s

Achie"es streamlined production

WHAT IT +,ES

Stale en"ironment

WHAT IT ASS'MES


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T3E TO4OTA PRODUCTION S4STE5

"ased on t)o philosophies6

7- Elimination of )aste

Respect for people


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ELI5INATION O2 8ASTE

9- 2ocused factory net)or+s

:roup technolo&y

;uality at the source

#IT production

Uniform plant loadin&


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5INI5I>IN: 8ASTE6

2OCUSED 2ACTOR4

NET8OR


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5INI5I>IN: 8ASTE6 :ROUP TEC3NOLO:4 (PART 9,

Usin& Departmental Specializationfor plant layout can cause a lot of

unnecessary material mo!ement

Saw Saw

Lathe PressPress

Grinder

LatheLathe

Saw

Press

Heat Treat

Grinder

'ote how the flow lines are going back and forth


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5INI5I>IN: 8ASTE6 :ROUP TEC3NOLO:4 (PART 7,

Re!isin& %y usin& Group Technology Cellscan reduce mo!ement and impro!eproduct flo)

Press

Lathe

Grinder

Grinder

A

2

BSaw

Heat Treat

LatheSaw Lathe

PressLathe

1


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M()(M(*()+ ,A%'E:#)(OM P$A)' $OA/()+ 01E(2#)KA

ot uni!orm "an# $nits Feb# $nits %ar# $nits Total

1&2'' (&)'' *&('' +&'''

$ni!orm "an# $nits Feb# $nits %ar# $nits Total

(&''' (&''' (&''' +&'''

Suppose )e operate a production plant that produces a sin&leproduct- The schedule of production for this product could %e

accomplished usin& either of the t)o plant loadin& schedules

%elo)-

3o) does the uniform loadin& help sa!e la%or costs?

or


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M()(M(*()+ ,A%'E: ()E)'O&1(/E% PO$EM%

,or- in

.ro/ess

0ueues

ban-s

Chan3eorders

4n3ineerin3 desi3n

redundan/ies

Vendor

delin0uen/ies

S/ra.

5esi3n

ba/-lo3s

%a/hine

downtime

5e/ision

ba/-lo3s

6ns.e/tion

ba/-lo3s

Pa.erwor-

ba/-lo3

E.ample6 "yidentifyin& defecti!e

items from a !endor

early in the

production process

the do)nstream )or+

is sa!ed

E.ample6 "yidentifyin& defecti!e

)or+ %y employees

upstream* the

do)nstream )or+ is

sa!ed


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5INI5I>IN: 8ASTE6


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DETER5ININ: T3E NU5"ER O2


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'1E )#ME O KA)A) 6A/%E'%

C

SDL

k

21

/ontainertheo!Si7e

sto/-Sa!etytimeleaddurin3demand48.e/ted

+=

+=

k = Num%er of +an%an card sets (a set is a card,

D@ A!era&e num%er of units demanded o!er some time

period

L@ lead time to replenish an order (same units of time asdemand,

S@ Safety stoc+ e.pressed as a percenta&e of demand

durin& leadtime

C@ Container si=e


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E7AMP$E O KA)A) 6A/ /E'EM()A'(O):PO$EM /A'A

A s)itch assem%ly is assem%led in %atches of units froman /upstream1 assem%ly area and deli!ered in a specialcontainer to a /do)nstream1 control'panel assem%ly

operation

The control'panel assem%ly area reuires B s)itchassem%lies per hour

The s)itch assem%ly area can produce a container ofs)itch assem%lies in 7 hours

Safety stoc+ has %een set at 9 of needed in!entory


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EA5PLE O2


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RESPECT 2OR PEOPLE

Le!el payrolls

Cooperati!e employee unions

Su%contractor net)or+s

"ottom'round mana&ement style

;uality circles (Small :roup In!ol!ement Acti!ities orS:IAFs,


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TO4OTA PRODUCTION S4STE5FS 2OUR RULES

9- All )or+ shall %e hi&hly specified as to content*seuence* timin&* and outcome

7- E!ery customer'supplier connection must %e direct*

and there must %e an unam%i&uous yes'or'no )ay tosend reuests and recei!e responses

G- The path)ay for e!ery product and ser!ice must %esimple and direct

- Any impro!ement must %e made in accordance )iththe scientific method* under the &uidance of ateacher* at the lo)est possi%le le!el in theor&ani=ation


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LEAN I5PLE5ENTATION RE;UIRE5ENTS6 DESI:N

2LO8 PROCESS

Lin+ operations

"alance )or+station capacities

Redesi&n layout for flo)

Emphasi=e pre!enti!e maintenance

Reduce lot si=es

Reduce setupHchan&eo!er time


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LEAN I5PLE5ENTATION RE;UIRE5ENTS6 TOTAL

;UALIT4 CONTROL

8or+er responsi%ility

5easure S;C

Enforce compliance

2ail'safe methods

Automatic inspection


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LEAN I5PLE5ENTATION RE;UIRE5ENTS6 STA"ILI>E SC3EDULE

Le!el schedule

Underutili=e capacity

Esta%lish free=e )indo)s


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LEAN I5PLE5ENTATION RE;UIRE5ENTS6


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LEAN I5PLE5ENTATION RE;UIRE5ENTS6 8OR< 8IT3

$ENDORS

Reduce lead times

2reuent deli!eries

Pro0ect usa&e reuirements

;uality e.pectations


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LEAN I5PLE5ENTATION RE;UIRE5ENTS6 REDUCE

IN$ENTOR4 5ORE

Loo+ for other areas

Stores

Transit

Carousels

Con!eyors


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$EA) (MP$EME)'A'(O) E8#(EME)'%:(MPOE PO/#6' /E%(+)

Standard product confi&uration

Standardi=e and reduce num%er of parts

Process desi&n )ith product desi&n

;uality e.pectations


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CONCURRENTL4 SOL$E PRO"LE5S

Root cause Sol!e permanently

Team approach

Line and specialist responsi%ility

Continual education


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5EASURE PER2OR5ANCE

Emphasi=e impro!ement

Trac+ trends


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LEAN IN SER$ICES (EA5PLES,

Or&ani=e Pro%lem'Sol!in& :roups

Up&rade 3ouse+eepin&

Up&rade ;uality

Clarify Process 2lo)s

Re!ise Euipment and Process Technolo&ies


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LEAN IN SER$ICES (EA5PLES,

Le!el the 2acility Load

Eliminate Unnecessary Acti!ities

Reor&ani=e Physical Confi&uration

Introduce Demand'Pull Schedulin&

De!elop Supplier Net)or+s


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References: Operations Management forCompetitive AdvantageBy Chase, Jacobs & A!i"ano, ##e

HOPE YO E!"OYED THE CL#SS$ %EST&O!S PLE#SE

T3AN< 4OU

6366849 Lean Production

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