A training on 3 m’s in lean management

A training on Muda, Mura & Muri in Lean manufacturing

1. A Training on 3 M’s in Lean Management By Pramod A

2. Lean Management Lean Management of “Lean” is the optimal way of managing a process through the removal of wastes and Implementing a flow. More value with Less work Lean Manufacturing is mostly derived from Toyota Production System (TPS) and identified as “Lean” only after 1990. Ultimate goal is the removal of all wastes in the Process.

3. Toyota Production System Make what the customer needs, when it is needed, and in right amount. Minimize Inventories. Full utilization of all Potentials. Building Quality in the process and Prevent errors from happening. Reduction of through put time.

4. Lean Production - TPS The Main goals of TPS are to eliminate 3 M’s which are, Muri ( Overburden or stress in the system) Mura (Inconsistency, Un-evenness) Muda (Waste) Ultimate Goal is to design a process that runs smoothly, without stress and eliminates wastes.

5. 3 M’s

6. Muda What is Muda?... Work that does not add any value to the product or the activities which the customer is not paying for.

7. Economic Value of Muda Every Business activities absorb resources and each resource has a cost. Every waste has a cost and that is a direct loss to the company. Economic value of the waste in a process industry are in the range of 10% - 35% of annual turnover

8. Types of Muda 7 Types of Muda

9. Muda of Motion Movement that does not add value. Searching of Files Gathering Information Looking through manuals and catalogs Handling Paperwork “The Movement of People Within the Workspace”

10. Muda of Waiting Waiting constricts smooth flow. it interrupts the work rhythm Job waiting to be loaded into a machine Products waiting for inspection W aiting for raw materials and parts Customer Response

11. Muda of Transport Transportation adds time to the process without increasing value, and creates an opportunity for damage to occur. Poor plant layout leads to transportation wastes, and waste can be removed by achieving the shortest distance in a straight line . " The Unnecessary Movement of Materials" Some results of unnecessary transportation: cost damage time lost spillage wasted investment in logistic equipment

12. Muda of Over Production "Producing More than Required Amount" Overproduction arises from fear or concerns of stock outs or a misunderstanding of demand A process that continues when its output is not required causes excess inventory . Over-production is generally regarded as the worst type of waste, it leads to all the other wastes. “Produce the right amount at the right time.”

13. Muda of Inventory Get rid of 'just in case inventory'; it ties up cash and requires additional storage facilities. Excess storage can cause stock damage, and materials can degrade in store. O ld stock items that aren’t currently used in production. N eeds space. Costs money. Requires finding. Needs intermediate storage and people to move them. can hide problems "Stock that is Not Required for Customer Orders"

14. Muda of Over Processing "Doing More than needed to Meet the Customer Requirement" Efforts that create no value from Customers view point C ompleting two or three inspections , Measuring components more than once Use of Outdated standard forms

15. Muda of Defects Producing parts, products, or services that are defective results in scrap and rework; it also wastes supplies and leads to customer dissatisfaction . M aking items to the wrong specification The production of defects or scrap results in: additional materials usage additional transportation additional control space for quarantined stores space for repairing Reduce defects and scrap through: Search for and elimination of causes B uild in Quality (QA process sheets ) "Doing Nice or Do It Twice"

16. Mura Eliminating unevenness or irregularities in any operation or process is one of the main principles of the Just-In-Time system, the main pillar of the Toyota Production System . Mura is the waste of unevenness or inconsistency.

17. Muri Muri is the Over Burden on equipment, Facilities & People caused by Muda and Muda. Pushing a machine or person beyond its limits.

18. Muri Results Overburdening peoples results in safety and quality problems. Overburdening machines causes breakdown and defects.

19. Lean Solutions First you must see it – MAKE IT VISIBLE!

20. Lean Solutions - Value Stream Mapping You can See and Identify Waste as you connect your processes from start to finish

21. Lean Solutions Problem Solve Plan Do Check Ac t

22. Lean Solutions Keep watching