Lean Manufacturing Presentation power point

Lean

1. Presentation on
Lean Manufacturing
Presented by:-
Nupur Mehta
M.tech 1
st
yr (CAD/CAM)
Enroll no.-1313201002

2. Definition
Lean Manufacturing – A way to eliminate waste
and improve efficiency in a manufacturing
environment.
Lean focuses on flow, the value stream and
eliminating muda, the Japanese word for waste.
Lean manufacturing is the production of goods
using less of everything compared to traditional
mass production: less waste, human effort,
manufacturing space, investment in tools,
inventory, and engineering time to develop a new
product.

3. Lean and Just-in-Time
Lean was generated from the Just-in-time
(JIT) philosophy of continuous and forced
problem solving.
Just-in-time is supplying customers with
exactly what they want when they want
it.

4. What is Waste?
Waste is anything that
happens to a product
that does not add
value from the
customer’s
perspective.
Products being stored,
inspected or delayed,
products waiting in
queues, and defective
products do not add
value.

5. Seven Wastes
Overproduction – producing more than the
customer orders or producing early. Inventory of
any kind is usually waste.
Queues – idle time, storage, and waiting are wastes
Transportation – moving material between plants,
between work centers, and handling more than
once is waste
Inventory – unnecessary raw material, work-in-
process (WIP), finished goods, and excess
operating supplies
Motion – movement of equipment or people
Overprocessing – work performed on product that
adds no value
Defective product – returns, warranty claims,
rework and scrap

6. Origins
Lean Manufacturing is
sometimes called the
Toyota Production
System (TPS)
because Toyota
Motor Company’s Eiji
Toyoda and Taiichui
Ohno are given
credit for its
approach and
innovations.

7. Toyota Production System
 Toyota Production System requires
that activities, connections, and flow
paths have built-in tests to signal
problems automatically, gaps become
immediately evident.
Results of the TPS are improvements
in reliability, flexibility, safety, and
efficiency.
These lead to increase in market
share and profitability.

8. Key Lean Manufacturing Techniques
5S
Single Minute Exchange of Dies
Kanban
Cellular Manufacturing

9. 5S
Strategy for creating a well organized, smoothly
flowing manufacturing process

10. 5S Examples
Before After

11. Benefits of 5S
Increases organization and
efficiency
Avoids wasted motion
Increases safety
Eliminates unnecessary inventory
Offers improvements at an
inexpensive cost

12. Single Minute Exchange of Dies (SMED)
Method that focuses on the rapid conversion
from manufacturing one product to the next

13. Benefits of SMED
Increases throughput by reducing setup
times
Eliminates setup errors
Increases safety
Reduces the cost of setups
Reduces waiting times and inventory
buildups
Decreases the required skill level of the
operators

14. Kanban
A system that uses replenishment signals
to simplify inventory management
Signals (usually cards) hold product details
What to make, when to make it, how much to
make, and where to send it
Cards stay attached to a bin that holds the
product
When bin is empty, it is returned to the start
of the assembly line for replenishment
Full bins are returned to the customer, and the
cycle continues

15. Benefits of Kanban
Highly visible systems
Simple, effective, and inexpensive
Reduces inventory and eliminates
stock-outs
Improves the quality of service
Improves lead times

16. Cellular Manufacturing
Dividing the manufacture of products
into semi-autonomous and multi-skilled
teams known as work cells

17. Cellular Manufacturing Example
Functional Layout Cellular Layout

18. Benefits of Cellular Manufacturing
Simplifies material flow and
management
Reduces interdepartmental travel
Reduces throughput time
Reduces lot sizes
Simplifies scheduling

19. Lean Manufacturing
Advantages and Disadvantages
Advantages:
Increased overall
productivity
Reduced amount of floor
space required
Reduced manufacturing
lead time
Improved flexibility to
react to changes
Improved quality
Disadvantages:
Difficulty involved with
changing processes to
implement lean principals
Long term commitment
required
Very risky process -
expect supply chain issues
while changing over to
lean

20. How People Benefit from Lean
Element Traditional Lean Improvement
Communication Slow & UncertainFast & Positive Quality &
Coordination
Teamwork Inhibited Enhanced Effective Teams
Motivation Negative, ExtrinsicPositive, IntrinsicStrong Motivation
Skill Range Narrow Broad Job Enrichment
Supervision Difficult and
Fragmented
Easy & LocalizedFewer Supervisors

21. How Customer’s Benefit from Lean
Element Traditional Lean Improvement
Response Weeks Hours 70-90%
Customization Difficult Easy Competitive
Advantage
Delivery Speed Weeks-Months Days 70-90%
Delivery
Reliability
Erratic Consistent & High Up to 90%
Delivery
Quantities
Large Shipments JIT as Required Locks in JIT
Customers
Quality Erratic Consistent & High Delighted
Customers

22. Storage Systems
Function – to store materials (e.g.,
parts, work-in-process, finished
goods) for a period of time and
permit retrieval when required.
Used in factories, warehouses,
distribution centers, wholesale
dealerships, and retail stores.
Automation available to improve
efficiency.

23. Automated Storage Systems
Mechanized and automated storage
equipment to reduce the human
resources required to operate a
storage facility.
Level of automation varies
In mechanized systems, an operator
participates in each storage/retrieval
transaction.

24. In highly automated systems, loads are
entered or retrieved under computer
control.

25. Objectives and Reasons for
Automating Storage Operations
To increase storage capacity
To increase storage density
To recover factory floor space
currently used for WIP
To improve security and reduce
pilferage
To reduce labor cost and/or
increase productivity

26. To improve safety
To improve inventory control
To improve stock rotation
To improve customer service
To increase throughput

27. Types of Automated Storage
System
1.Automated Storage/Retrieval
System (AS/RS)
Rack system with mechanized or
automated crane to store/retrieve
loads
2.Carousel Storage System
Oval conveyor system with bins to
contain individual items

28. AS/RS Types
Unit load AS/RS - large
automated system for pallet loads
Deep-lane AS/RS - uses flow-
through racks and fewer access
aisles
Miniload AS/RS - handles small
loads contained in bins or drawers
to perform order picking

29. Man-on-board AS/RS - human
operator rides on the carriage to pick
individual items from storage
Automated item retrieval system
- picks individual items
Vertical lift storage modules
(VLSM) - uses a vertical aisle rather
than a horizontal aisle as in other
AS/RS types

30. AS/RS Applications
1.Unit load storage and retrieval
Warehousing and distribution operations
AS/RS types: unit load, deep lane (food industry)
2.Order picking
AS/RS types: miniload, man-on-board, item
retrieval
3.Work-in-process storage
Helps to manage WIP in factory operations
Buffer storage between operations with different
production rates
Supports JIT manufacturing strategy
Kitting of parts for assembly

31. Thank you