MGT 187 - Lean Manufacturing | Operations Management

MGT 187 - Lean Manufacturing.pptx

1. LEAN MANUFACTURING GR 1 - ELON MUSK

2. Define Lean Manufacturing: To provide a clear and comprehensive understanding of Lean Manufacturing principles and its underlying philosophy. Explore Historical Context: To trace the origins and evolution of Lean Manufacturing, highlighting its key developments, influences, and pioneering figures. Identify Core Principles: To outline the five principles of Lean Manufacturing. Recognize the Different Types of Waste: To identify and discuss the types of waste that Lean Manufacturing seeks to eliminate. Understand Tools and Techniques: To explore various tools and techniques used in Lean Manufacturing to improve efficiency and reduce waste. Evaluate Advantages and Disadvantages: To assess the benefits and drawbacks of implementing Lean Manufacturing in businesses. Examine Real-World Applications: To analyze recent business news and case studies to illustrate the practical application of Lean Manufacturing principles. LEARNING OBJECTIVES

3. “Lean” originates from Old English hlinian , meaning " to incline or rest ," evolving to imply minimal excess . " Manufacturing " comes from the late 17th century, meaning "to convert material into usable form" and later, "to produce on a large scale” . LEAN MANUFACTURING Lean manufacturing, a sustainable approach , focuses on eliminating waste and inefficiencies definition, description, etymology, philosophy Lean manufacturing is a methodology that minimizes waste and maximizes productivity in manufacturing systems. Its benefits include reduced lead times, lower operating costs, and improved product quality. The philosophy behind lean, developed by Toyota, is centered on efficiency and eliminating waste . Rooted in Japan's resource scarcity, lean focuses on three main principles: Elimination of Waste Empowerment of Workers and Suppliers Continuous Improvement ( Kaizen )

4. GET TO KNOW LEAN MANUFACTURING BETTER.

5. HISTORICAL CONTEXT PIONEERING FIGURES Post-WWII Japan: Emerged as a response to American mass production. Toyota’s Innovation: Taiichi Ohno developed the Toyota Production System (TPS) and "Just-in-Time" (JIT) methodology to produce only what's needed, when needed, reducing waste. Taiichi Ohno James Womack Daniel T. Jones Daniel Roos Known as the father of the Toyota Production System Industrial engineer and executive at Toyota. He pioneered Just-In-Time manufacturing, transforming production efficiency. Often regarded as the Father of the Lean Movement Co-authored The Machine That Changed the World Founded the Lean Enterprise Institute, spreading lean principles globally. Founder and chairman of the Lean Enterprise Academy Has been instrumental in promoting lean manufacturing concepts. An American engineer and co-author of The Machine That Changed the World Has made significant contributions to engineering education and lean production.

6. THE PRINCIPLES OF LEAN MANUFACTURING Identify Value: Focus on what the customer needs and eliminate non-value-adding activities. Map the Value Chain: Visualize every step in your process to spot and remove waste. Create Continuous Workflow: Ensure smooth, uninterrupted workflows by eliminating bottlenecks. Establish a Pull System: Produce only in response to demand, avoiding overproduction. Continuous Improvement: Involve everyone in ongoing process optimization. Source:https://theleanway.net/The-Five-Principles-of-Lean

7. TIM WOOD Seven prominent types of waste to be eliminated from the supply chain as identified by Fujio Cho; Hi! I’m TIM WOOD. T I M W O O D RANSPORTATION - NVENTORY - OTION - AITING - VERPRODUCTION - VERPROCESSING - EFECTS - Unnecessary movement of materials due to inefficient layouts. Holding excess stock from poor production planning. Wasted movements of people, like extra walking to retrieve materials. Idle time for workers and machines due to delays or uncoordinated tasks. Producing more than customer demand, leading to excess inventory. Extra steps or inefficient processes requiring more labor/time. Producing defective items, leading to wasted resources and rework.

8. Japanese term for fail- safing “Mistake-proofing.” Simple devices or systems that are incorporated into a process to prevent inadvertent mistakes by those providing a service as well as customers receiving a service Poka-Yoke Low-investment, high-impact lean manufacturing tool. Activities build the discipline needed for substantial and continuous improvement by creating and sustaining efficient and effective work areas 5S Also known as ‘end-to-end’ system mappingVisually maps a product/service ‘production’ path from start to finish Value Stream Mapping Japanese term for ‘the actual place.’ A practice where managers go to the actual place where work is done to observe processes, engage with employees, and identify opportunities for improvement Gemba TOOLS AND TECHNIQUES

9. Japanese term for fail- safing “Mistake-proofing.” Simple devices or systems that are incorporated into a process to prevent inadvertent mistakes by those providing a service as well as customers receiving a service Andon Also known as Level Scheduling. A form of production scheduling that purposely manufactures in much smaller batches by sequencing or mixing product variants within the same process Heijunka Japanese term for sign or instructional card The cards makes up the kanban pull system—- an inventory control system that uses a signaling device to regulate flowsControls the flow of work and materials through a production process Kanban Focuses on proactive and preventive maintenance to maximize the operational efficiency of equipment Total Productive Maintenance TOOLS AND TECHNIQUES

10. Focuses on continuous improvement involving everyone in the organization Kaizen Identifies the part of the manufacturing process that limits overall throughout and focuses on improving the performance of that part Bottleneck Analysis TOOLS AND TECHNIQUES

11. ADVANTAGES DISADVANTAGES It saves time and money Environmental friendly Improved customer satisfaction Employee safety and well-being Hinders future development Difficult to standardize

12. Through lean manufacturing in which they help communities to be more resilient, highlighting environmental management, and a cycle of lending a helping hand to protect the sport as well as the Earth. BUSINESS NEWS The company embedded the principles of lean manufacturing advance culture where everyone has the same objective to stop defects, improve operation processes, and waste elimination to attain excellence in their operations

13. CONCLUSION After going into the intricacies of Lean Manufacturing, it becomes evident that this approach is more than just a set of tools and techniques. It's a philosophy that prioritizes value, eliminates waste, and fosters continuous improvement. While the benefits are undeniable, such as increased efficiency, reduced costs, and improved quality, it's crucial to recognize that successful implementation requires a delicate balance. Overemphasizing efficiency can lead to unintended consequences like employee burnout and hindered innovation. The key lies in striking the right equilibrium, ensuring that the pursuit of lean principles doesn't compromise the well-being of employees or the long-term sustainability of the organization. Ultimately, Lean Manufacturing offers a powerful path to operational excellence, but it must be embraced with a mindful and holistic approach.

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