Lean Production(MUDA)

Ijaz Ul HasanNPO Pakistan

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Why we produce ? ? ?

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What is Lean• Lean = waste-less • Waste = non value-added = MUDA in Japanese

• Productivity =

• Maximize “Productivity” Minimize “Input”, if “output” is fixed Constant “Input”, more “output”

Output

Input

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• Input ? ? ? ?MachinesMan (Human Resources)MaterialMethodMoney

What Else ????????????

Wastages (MUDA)

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Wastages (MUDA)

Any activity or process that adds costs but adds no value (for the customer).

There are a lot of “MUDA” in our business. Do not miss (even) small “MUDA” To realize “Lean” “Kaizen” is mandatory Kaizen by Genba + Management support

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Non Value Added (Wastages)

• Transportation• Inventory /WIP• Motion• Waiting• Over Production• Over Processing• Defect• Not used creativity of employees

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Transportation

• Unnecessary movement of information, products or components from one area to another.

• Unnecessary transport usually occur together with unnecessary movement, product damages, lost parts and systems, which detect movements.

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W E

134'-0"

39'-10"

17'-2"

17'-0"

Front Office8ft. 10.49in. X 14ft. 0.00in.

Wash room4ft. 0.00in. X 7ft. 0.00in.

Machin Shop16ft. 10.49in. X 78ft. 0.00in.

Store Room:14ft. 11.24in. X 40ft. 0.00in.

Welding Area24ft. 0.00in. X 46ft. 10.49in.

24'-0"

Up

Assembly Area:23ft. 10.49in. X 46ft. 0.00in.

Room:9ft. 4.49in. X 12ft. 10.49in.

11'-1 11/16"

Paint Area23ft. 6.00in. X 58ft. 0.00in.

78'-0"

S

136 ft

10 ft

10 ft

5 ft

10 ft

100 ft

50 ft

80 ft

25 ft

65 ft

55 ft

39'-10"

17'-0"

Front Office17ft. 0.00in. X 12ft. 0.00in.

Welding Section-II17ft. 6.00in. X 99ft. 0.00in.

Store Room:14ft. 11.24in. X 40ft. 0.00in.

24'-0"

Up

11'-1 11/16"

212'-0"

S

Receiving/Grinding

Gas Cutting17ft. 6.00in. X 62ft. 0.00in.

Welding Section-I17ft. 6.00in. X 24ft. 0.00in.

Paint Section23ft. 6.00in. X 53ft. 0.00in.

Finished product store23ft. 6.00in. X 17ft. 6.00in.

Generator

Welding Room:10ft. 6.00in. X 12ft. 0.00in.

1'-6"

Shaper

Milling

UpStairs

Assembly Area14ft. 0.00in. X 50ft. 0.00in.

7'-0"

3'-6"

Drilling Area14ft. 0.00in. X 22ft. 0.00in.

Transportation of main part of one of the Agri Implement

After: 222 feet

Before: 546 feet

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• Difficult to transport in our local industry

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Follow the bouncing paperwork

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Inventory/WIP

• Inventory is the quantity of items on stock, which are required to manufacture a product. These goods also cause costs to the company.

• When they are not used they utilize valuable warehouse space, may become obsolete and may require raw materials, which cannot be used for more important goods.

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• Competitive organizations make sure that their system controls the inventory, so that money is not being wasted on unwanted items or build groups.

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Scrap

Work in process inventory level(hides problems)

Unreliable Vendors Capacity Imbalances

Lowering Inventory Reduces Waste

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Scrap

Reducing inventory revealsproblems so they can be solved.

Unreliable Vendors Capacity ImbalancesWIP

Lowering Inventory Reduces Waste

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Scrap

Reducing inventory revealsproblems so they can be solved.

Unreliable Vendors Capacity ImbalancesWIP

Lowering Inventory Reduces Waste

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Motion

• Unnecessary movements occur when employee is moving around his work space and as a result of this may waste time and effort.

• All kind of unnecessary motion is being caused by poor working standard practices, poor (not optimal) process design or work area layout.

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After improvementBefore improvement

The crouching posture is MUDA of motion

Parts rack

Up

I can take it easily

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Waiting

• Each step in a manufacturing process is dependent on the upstream and downstream stage processes.

• If employees, equipment, information or materials of the production process are delayed, production time is wasted and the cost of production will be increased.

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Waiting eliminated

Turner operating two machines now

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Over Production

• Overproduction arises when the company is producing more than the customer really requires.

• This may include both the production of products or components for which there are no orders, as well as production of more items than currently needed.

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Over Production

• This is the worst kind of waste, because it usually multiplies other kinds of waste. It increases rework rate, inventory, processing, waiting, as well as unnecessary motion and transportation

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Over Processing

• Over processing includes extra steps in the manufacturing process which need to be taken.

• It can also mean producing products of a higher quality than required. This may be due to incorrectly used equipment, errors in rework process, poor process design or bad communication.

• This can be also result of not checking what are the real customers’ requirements.

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Example

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Non Conformance (Defects)

• Rework is required when products and components are defective or damaged and they have to be reworked.

• Defects are caused by bad manufacturing processes (caused by human or machine errors).

• Rework takes additional time and therefore increases manufacturing costs of the final product. In worst case scenario the items have to be discarded.

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Un Controlled Process

• Defects occur due to – Owner/manager has

no training in this process!

– Mishandling– Lack of Knowledge

Inputs

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Not Used: Creativity Of Employees• This waste involves loss of time, skills, ideas,

improvements and learning opportunities by not taking employees opinion into the account.

• This is result of employees not taking part in design of manufacturing processes. Only in this way the ideas can develop, which are needed to eliminate and avoid the other seven sources of waste.

• This helps to improve your processes in continuous manner by increasing the available knowledge and creativity of you employees.

• In addition it helps in principle to increase the level of employees’ satisfaction at work.

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• People who work in the process and know the process best (both the strengths and weaknesses).

• Do they have the tools, training and permission to systematically improve their process?

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Thanks

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