lean production and its methods PPT.pptx

introduction of lean production

1. Production The processes and methods used to transform tangible inputs (raw materials, semi-finished goods) and intangible inputs (ideas, information, knowledge) into goods or services.

2. Activity Relate this activity in Everyday Life: Example: Making a Cup of Tea (Lean at Home) Traditional Method: Someone who doesn’t know the making of tea without any guidelines, might boil too much water, use more tea leaves than necessary, and let the tea steep for too long, wasting time and resources. Lean Method: Someone who knows the making of tea with proper guidelines Shows how using the right amount of water, tea leaves, and optimal steeping time creates the perfect cup of tea efficiently, with no waste .

3. Relate Lean Production Cost Reduction: Lean Production reduces costs by minimizing waste, leading to lower prices for consumers. Quality Improvement: continuous improvement leads to higher quality products, which increases customer satisfaction.

4. LEAN PRODUCTION Lean production originated in the manufacturing plants of Japan but has now been adopted well beyond large manufacturing activities. Lean production covers various techniques businesses use to cut down waste and increase efficiency. It aims to reduce the time a product takes to develop.

5. BENEFITS OF LEAN PRODUCTION Waste Reduction: Lean Production helps cut down on waste, whether it’s time, materials, or effort.- Example: Imagine making a sandwich. If you prepare only the ingredients you need and use them efficiently, you avoid wasting food. Similarly, in a factory, Lean Production ensures only necessary materials are used, reducing waste.

6. Cost Reduction By using resources more efficiently, Lean Production lowers costs. Example: Think of a school that prints only the exact number of worksheets needed for a class. This saves money on paper and ink. Similarly, businesses save money by producing only what they need, avoiding excess.

7. Improved Quality Lean Production focuses on doing things right the first time, which improves product quality. Example: If you carefully check your homework for mistakes before handing it in, you’re likely to get a better grade. In the same way, companies using Lean Production inspect products as they are made, catching errors early to ensure higher quality.

8. Faster Production Times Lean Production speeds up the process of making goods. Example: Think of making pancakes. If you have all ingredients ready and follow a smooth process, you can make pancakes faster. Similarly, in a factory, Lean Production organizes work so products are made quickly and efficiently.

9. Employee Involvement Example: Suppose your teacher lets everyone in the class suggest how to arrange the classroom to make it more comfortable. When students feel involved in the decision, they’re more likely to keep the classroom neat. In Lean Production, workers are encouraged to share ideas for making their work easier and more efficient, leading to a better work environment and improved production.

10. Flexible Production Example: Imagine running a lemonade stand. If you notice customers prefer strawberry lemonade over regular, you can quickly switch to making more strawberry lemonade. In Lean Production, businesses are flexible and can quickly change what they’re making based on what customers want, without wasting time or resources.

11. Methods of Lean production Kaizen Just-in-time inventory control Cell production

12. Example Improving Study Habits Imagine you’re trying to improve your grades. Instead of making a drastic change, like studying for five hours every day right away, you start by adding just 10 extra minutes of study time each day. Over time, this small change adds up, and you find yourself understanding the material better and getting better grades without feeling overwhelmed.

13. Kaizen Kaizen means 'continuous improvement' in Japanese and its focus is on the elimination of waste. Keep improving bit by bit in the production process. Workers meet regularly to discuss problems and possible solutions.

14. Example School Supplies Imagine you have a big school project due next week. Instead of buying all your supplies (like poster boards, markers, and glue) at the start of the school year and storing them until you need them, you go to the store and buy exactly what you need right before you start the project. This way, you don’t waste money on supplies you might not use or that could get lost or damaged over time.

15. Just-in-time production Raw materials are delivered just in time by suppliers for production. Reliable suppliers are needed for this to work.

16. Example Making Pizzas in a Restaurant Imagine a pizza restaurant where each group of workers is responsible for a specific step in the pizza-making process. One cell is responsible for preparing the dough, another for adding the toppings, and a third for baking the pizzas. Each cell works independently but in a coordinated way, so the pizzas move smoothly from one cell to the next until they’re ready to serve. This allows the restaurant to make pizzas more quickly and efficiently, with each team focusing on their specific tasks.

17. Cell production Manufacturing approach where the production process is broken down into smaller units, or "cells." Each cell is a group of workers and machines arranged to perform a specific set of tasks, allowing for more efficient production and better quality control.