WELCOME TO THE PRESENTATIONON

APPLICATIONS OF LEAN APPROACH

IN MANUFACTURING

COURSE NAME: Business Communication SeminarCOURSE NO: IPE-326

PRESENTED BYMEMBER’S NAME REG NO:

Ismam Ahmed 2012334062

Musaddeque Hossain 2012334063

Reduan Islam Hridoy 2012334065

Sabbir Ahmed 2012334064

DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERINGSHAHJALAL UNIVERSITY OF SCIENCE &TECHNOLOGY,

SYLHET

CONTENTS What is lean?Component of lean manufacturing7 types of wastesOrigin of lean5SBatch size reductionKanbanKaizanVisual contents(Andon,Footprint,Signage)Cellular plantLean in Bangladesh

1

It is a comprehensive set of techniques that are used to identification and stady

elimination of wastes,improvement of quality,reduction of production and cost

What is lean

Elimination of waste

Improve of quality

Identification

Reduction cost

2

TPS Definitions of Waste(7 types)

1. Overproduction2. Waiting, including time in

queue3. Transportation (between

workstations, or between supplier and customer)

4. Non-value-adding activities5. Inventory6. Waste motion7. Cost of poor quality: scrap,

rework, and inspection

“Anything that adds Cost to the product without adding Value”

3

Team work

Origin of Lean

Statiscal Process ControlPlan-Do-Check-Act cycle

Ass

embl

y lin

eS

tand

ardi

zed

Wor

kTi

me

stud

y

Interchangeable parts

Work Division

“Doing more with less”

JITJidokaKaizenSMED

Pull system

4

Waste is Often Built Into Jobs

Gilbreth study on brick setup

Need 7-8 sec to setup a single brick Need 2-3 sec to setup a single brick

5

Lean ToolsWorkplace Organization: 5S

Lean Tools

Kanban

Kaizen

Work balancing (TAKT Time)

Visual Management

Set-up Eeduction (SMED)

Heijunka

Batch Size Reduction

Standardized Work

Error-Proofing (Poka-Yoke)

Total Productive Maintenance (TPM)

Jidoka (autonomotion)

6

Inventory level

Delivering smaller quantities can reduce inventory levels

Inventory level

Batch Size Reduction

Lower Scrap

Lower holding cost

Space utilization

Higher productivity

7

Jidoka(Autonomation)

AutonomationAutomation

+ Human

intelligence

A level of human intelligence is transferred into automated machinery

Practice of stopping a manual line or process automatically

Frees the operator from watching the machine

8

Plate

B

Jidoka(Autonomation)9

Before JIDOKA

After Jidoda

SUST IPE

Sensor

Stopped10

SIGNBOARD

KAN署名する BANボード+

=

KANBAN

Is a “signal” that: Authorizes production Authorizes movement Visualize current position Drives continuous improvement

Pigon hole Signal Sticky notes box

11

KANBAN

Pending Analysis Development TestDoing Done Doing Done

p11p4

p12

p14

p13p5

p8

p2

p9

p10

p7

p1

p3p6

Where is Product-3 now?

Search the hole plant?

Check Kanban list?

12

p1 p2 p3 p4 p5 p6 p7 p8 p9 p10

p10

p11

p12

p13

p14

5S (Workplace Organization)

Organisation/Sort out

SEIRI

Orderliness/Systemize

SEITONStandardize

SEIKETSUSustain/

Discipline

SHITSUKEThe Cleaning/

Shining

SEISO

Developed by the Japanese Housekeeping System Helps Create a Better Working Environment and a Consistently High Quality Process Make faster assembly plant

13

5S Effect on Office

Clean top

Similar papers in files

Paper arranged

SEIRI SEITON SEISO SEIKETSU SHITSUKE

14

VISUAL CONTROLVisual Controls are simple signals that provide an immediate understanding of a situation or condition.

lightingSystem

Floor painting

PictureDiagram

Color coded tool

Andons SignageFootprint

Basically 3 types

15

Types of Andon

Coded signal lightsText Graphics

Visual Andon

Green - no problems

Yellow - situation requires attention, production flow at risk

Red - PRODUCTION STOPPAGE: IMMEDIATE ASSISTANCE REQUIRED

1

Display production data in real time. Calculate shift efficiencies and production targets.

Ideal for STOP / WAIT / GO signaling in busy factories Boost health and safety.

Coded Tones

Coded Tunes

Prerecorded Messages

Buzzers / Alarms

Audio Andon2

ANDON16

FOOT-PRINT

avoids employees wasting time looking for things

The workplace becomes clean and better organized.

Operation on the shop floor and office become easier and safer

Use colours as a guideline :

Light Blue - Raw parts/material

Black - Finished good/parts

Red - Non-conforming/KIV parts/material

White - Other than parts/material

Yellow – Border of work area

17

SIGNAGE

Provide information about:•hazardous and risky areas & installation• materials• safety measures• emergency exits, etc.

Signage

Displays Control

18

KAIZEN

ACT

Check

Do

Plan

Customar Need

Kaizen • is a tool to rapidly improve work as part of the PDCA cycle• is a tool for Continuos process• goals must align with the business objectives

KAI ZEN = Change for the better

19

Cellular Layout

• Produces families of parts within a single line• Reduce cycle time• Reduce time wastes

Storage

Drilling

joint

Threading

Turning PackingData

45%

65%

Assembly

check

Quality

20

Functional layoutCelluar Layout© Siemens Power Generation Systems

21

Reduction in unit production costCompany Name Before

Lean($)

After Lean($)

Reduction($)

As a %

1. Fashion Point Ltd.2. Texas Fashion Ltd.3. Beximco Fashions Ltd.4. Shanta Industries Ltd.5. DADA (Savar) Ltd.6. Shata WashWorks Ltd.7. Armana Fashions Ltd.8. Shanta Denims Ltd.9. PAXAR Bangladesh Ltd.

8.5011.04.40 10.01.403.500.87-4.50

7.009.003.208.001.303.000.84-3.00

1.502.001.202.000.100.500.03-1.50

17.618.127.220.07.114.23.4-33.3

Application of lean in Bangladeshi companies 22

Removes unnecessary activities Removes in-plant inventory Removes in-transit inventory Improves quality and reliability

JUST IN TIME (JIT)23

Traditional approach

JIT approach

stage A

orders

deliveries

orders

deliveries

JIT material flow

buffer inventory

stage B

buffer inventory

stage C

stage A stage Cstage B

24

POKA-YOKE(ERROR PROOF)

POKA-YOKE is part of the Just-in-time philosophy

POKA-YOKE reduces the defect rate that is part of the OEE rate

Weight

Dimensions

Shape

Suggested Methods:

25

Examples of POKE-YOKE26

THANK YOU

ANY QUESTIONS?