Practical Implementations of Lean Manufacturing Techniques

This presentation shows various lean manufacturing Techniques.

1. Practical implementation of lean manufacturing techniques By Dr. Peeyush Vats

2. Lean An essential element of all improvement approaches. Background resides in the practices of “TPS”

3. Traditional Thinking Vs Lean Thinking

4. What is Lean Manufacturing Lean manufacturing is a production process based on an ideology of maximising productivity while simultaneously minimising waste within a manufacturing operation. The lean principle sees waste is anything that doesn’t add value that the customers are willing to pay for The benefits of lean manufacturing include reduced lead times and operating costs and improved product quality.

5. What is Lean Manufacturing Lean is the specific way of thinking consisting a set of methods and operating principles to identify and eliminate waste in business process. The focus is on making processes more efficient in conjunction with a target to make specific reductions. Lean manufacturing entails streamlining processes and procedures to eliminate waste and thereby maximise productivity.

6. 3 Types of wastes Mura (Unevenness) Muri (Overburden) Muda (Process related waste)

7. 8 Wastages of lean manufacturing Unnecessary Transportation Excess Inventory Unnecessary movement of people, equipment or machinery Waiting Overproduction Over processing Defects Unused Talent

8. Why is Lean Manufacturing Important Less Process Waste Reduced Lead Time Less Rework Financial Saving Reduced Inventory Improve Quality Reducing Costs

9. 5 Key Issues in lean implementation Define Value Map the value stream Create Flow Establish the pull system Pursue Perfection

10. Define Value Providing the right products/services to the customer for the right price at the right time

11. Map the value stream The set of actions from a product/service concept of realization, order to delivery, raw material to finished goods etc.

12. Create Flow The seamless movement through a series of value creating steps.

13. Establish the pull system Acting only to satisfy the customer needs.

14. Pursue perfection Continuously and relentlessl y improving the value, value stream flow and pull in business operations along with associated reductions in defects .

15. L ean manufacturing tools and Techniques TPM 5 S SMED Kanban Kaizen Error proofing (Poka-yoke) JIT JIDOKA

16. L ean manufacturing tools and Techniques TPM: An important tool necessary to account for stopping sudden machine breakdown at shop floor. 5S: [ Seiri (Sort), Seiton (Straighten), Seiso (Shine and Sweep), Shitsuke (Standardize) and Seiketsu (Sustain)] SMED: Single minute exchange of die: To reduce any type of changeover time. Kanban: Visual aids: It is used to minimize the waste of WIP. Kaizen: Kaizen is the practice of continuous improvement. Error Proofing (Poka-Yoke): Mistake free at a very first attempt. JIT: JIT enables a industry to produce the product when the want. JIDOKA: JIDOKA highlights the causes of problem when they first occur. This helps in improving the process by eliminating root cause of defects.

17. The ways by which lean manufacturing can be implemented? Automation Continuous Improvement Flexibility Load Levelling Perfect First-Time Production or Service Quality Production Flow and Visual Control Pull Processing Supplier Relationships Waste Removal

18. Tips to implement lean process Design a simple manufacturing system Keeping searching for ways to improve Continuously implement design improvement

19. Advantages of lean manufacturing Save time and money Environment friendly Improved customer satisfaction

20. Disadvantages of lean manufacturing Employee safety and wellbeing Hinders future development Difficult to standardize

21. Thank You