LEAN MANUFACTURING

GROUP ‘H’ : VISHAL PANDITA (11MI3EP19) ARIJIT MITRA (11MT3EP17) BORA JAGANNADHA SWAMY (11MT3EP18) PRIYANKA (13RJ92J03) BIPUL SAHA (13RJ92R01)

WHAT IS LEAN MANUFACTURING ?

Lean Manufacturing is Business philosophy that continuously shortens the time between customer order and shipment by eliminating everything that increases the cost and time.

PRINCIPLES OF LEAN MANUFACTURING

Define value from the customer perspective Identify the value stream Make the process flow Pull from the customer Head toward perfection

3M’S OF LEAN

Lean manufacturing is a Japanese method focused on 3 M’s. “muda” – waste “mura” – inconsistency “muri” - unreasonableness

‘MUDA’ - WASTE Anything that does not add value to the product

can be defined as waste The implementation of lean manufacturing

techniques requires that all the wastes are identified and eliminated from the system

TYPES OF WASTE Waste of inventory (space and time) Waste of time (manufacturing time) Waste of materials (scrap) Waste of equipment (machine time) Waste of plant space and movement of materials and

objects Waste of labor (unnecessary action) Waste of capital (idle times of resources)

Overproduction

Waiting

Inventory

Transportation Motion

Over Processing

Rework

1

6

7

5 4

3

2

To produce sooner,fasteror in greater quantitiesthan customer demand.

Raw material, work in progressor finished goods

which is not having value added to it.

People or parts that wait for

a work cycle tobe completed.

Unnecessary movementof people, parts ormachines within

a process.Unnecessary movement of peopleor parts between processes.

Non rightfirst time.Repetitionor correctionof a process.

Processing beyondthe standardrequired by thecustomer.

An 8th waste is the wasted

potential of people

‘MURA’ - INCONSISTENCYInconsistency is a problem

that increases the

variability of

manufacturing. It is

observed in all

manufacturing activities

ranging from processing to

material handling to

engineering to management.

‘MURI’ - UNREASONABLENESS

An example of being unreasonable is by blaming someone for problems rather than looking at resolution of problems.

Management creates a non-blaming culture where : Problems are recognized as opportunities Its okay to make legitimate mistakes People are not problems, they are problem solvers Emphasis is placed on finding solutions instead of ‘who did it’

COMPARISON OF LEAD TIME

CustomerOrder

Waste ProductShipment

Time

CustomerOrder

ProductShipment

Time (Shorter)

Business as Usual

Waste

Lean Manufacturing

5 S’S OF LEAN

In implementing Lean, 5 S’s are frequently used to assist in the organization of manufacturing. The 5 S’s are from Japanese and are : “Seiri” – sort, necessary items “Seiton” - stabilize, efficient placement “Seison” - shine, cleanliness “Seiketsu” - standardize, continuous improvement “Shitsuke” - sustain, discipline

Lean manufacturing is not only a project or program but it is a way of thinking.The implementation of lean manufacturing will comprehend the following stages : Data collection Data analysis and development of solution Implementation

Data collection comprehends information gathered on the current state of facilities and operations. The output will be document describing all the important facts on the current state of the facilities and operations that are relevant for lean manufacturing.

DATA COLLECTION STAGE

This stage will have three documents as output : Evaluation document comprehending analysis

and calculation Design document proposing a solution Project implementation plan

DATA ANALYSIS STAGE

The following activities relating to lean manufacturing are performed : Execution of the project implementation plan Design and manufacture of special tools and materials

handling equipment Outsourcing of capex (if needed) Training of relevant staff

IMPLEMENTATION STAGE

GOALS OF LEAN MANUFACTURING

Improve quality Eliminate waste Reduce time Reduce total costs

The following steps should be implemented in order to create the ideal lean manufacturing system:

Design a simple manufacturing system Recognize that there is always room for

improvement Continuously improve the lean manufacturing

system design

STEPS TO ACHIEVE LEAN SYSTEMS

BENEFITS OF LEAN MANUFACTURING Productivity improvement Total manufacturing time saved Less equipment utilization (machine time, wear and tear) Less scrap – material cost saved Low inventory levels – stock holding cost saved Quality improvement Plant space saved – more efficient layout Better labor utilization Safety of operation

Thank you

• Specify value :

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, eliminating whenever possible those steps that do not create value.

• Create flow :

Make the value-creating steps occur in tight sequence so the product will flow smoothly toward the customer.

• Let the customer pull product through the value stream:

Make only what the customer has ordered.

• Seek perfection :

As value is specified, value streams are identified, wasted steps are removed, and flow and pull are introduced, begin the process again and continue it until a state of perfection is reached in which perfect value is created with no waste.

Design a simple manufacturing system

A fundamental principle of lean manufacturing is demand-based flow manufacturing. In this type of production setting, inventory is only pulled through each production centre when it is needed to meet a customer’s order.

• The benefits of this goal include

• decreased cycle time

• less inventory

• increased productivity

• increased capital equipment utilization

There is always room for improvement

The core of lean is founded on the concept of continuous product and process improvement and the elimination of non-value added activities. “The Value adding activities are simply only those things the customer is willing to pay for, everything else is waste, and should be eliminated, simplified, reduced, or integrated”. Improving the flow of material through new ideal system layouts at the customer's required rate would reduce waste in material movement and inventory.

Continuously improve

A continuous improvement mindset is essential to reach a company's goals. The term "continuous improvement" means incremental improvement of products, processes, or services over time, with the goal of reducing waste to improve workplace functionality, customer service, or product performance.

• Improve quality:

In order to stay competitive in today’s marketplace, a company must understand its customers' wants and needs and design processes to meet their expectations and requirements.

• Eliminate waste:

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

• Reduce time:

Reducing the time it takes to finish an activity from start to finish is one of the most effective ways to eliminate waste and lower costs.

• Reduce total costs:

To minimize cost, a company must produce only to customer demand. Overproduction increases a company’s inventory costs due to storage needs.