Download - Lean manufacturing techniques (1)
LEAN MANUFACTURING TECHNIQUES
Let’s Talk About Principles, Not About Tools…
Introduction to Lean Manufacturing
Kai = Change
Zen = Good
Change of betterment
Kaizen
Continuous Improvement Continual Improvement
Paradigm :The way you look at things
Shift = Change
Paradigm Shift
Gemba
Gemba – Real Place of work
Restaurant – Kitchen is real place of workManufacturing Company – Shop floor is real
place of workShopkeeper – Shop where exchange of
goods with customer.
Manufacturing
WhereverRaw material is converted
to finished products.
Process of ConversionRaw Material Finished Goods
Request for raw materialPotatoes are transported to gateGate supervisionTransport to quality divisionPotatoes are separated in batches for
supervisionSupervision for qualityTransport to storage areaPotatoes are stored in batchesTransport from Storage to Washing areaPotatoes are washed in batches thoroughly Remove from washing areaTransport to Pealing machine
Potatoes are pealed offTransport to slicing areaSettings are done for slicingPotatoes are slicedTransport to frying areaPotato slices are friedTransport to flavoring areaFlavors are added in proper amountTransport to packaging areaWafers are packed under maintained
conditionsTransport to distribution areasWafers packets are taken out of factory for
distributionFinal distribution
Traditional Cost Vs
Lean approach for Cost
Selling Price for Traditional Business
Cost of raw material +
cost of manufacturing +
Profit =
Selling Price
Selling Price for LEAN Way of Business
Profit =
Selling Price-
Cost of raw material -
cost of manufacturing
Did they add Value or Cost
Value: Wherever Physical or Chemical Property of Product is Changed for which customer is willing to pay
Process of ConversionRaw Material Finished Goods
Request for raw materialPotatoes are transported to gateGate supervisionTransport to quality divisionPotatoes are separated in batches for
supervisionSupervision for qualityTransport to storage areaPotatoes are stored in batchesTransport from Storage to Washing areaPotatoes are washed in batches thoroughly Remove from washing areaTransport to Pealing machine
CC
CC
CCCC
CCC
C
Potatoes are pealed offTransport to slicing areaSettings are done for slicingPotatoes are slicedTransport to frying areaPotato slices are friedTransport to flavoring areaFlavors are added in proper amountTransport to packaging areaWafers are packed under maintained
conditionsTransport to distribution areasWafers packets are taken out of factory for
distributionFinal distribution
VCC
V CV
CVC
VC
CC
Value Adding Ratio [VAR]
Value Adding TimeTotal Throughput Time
Where, throughput time is time taken for whole process
to get completed for single set/unit of product
VAR for different type of Organizations
Type of Organization
VAR (In %)
Traditional Organizations
0.1-1
Companies who have started Lean
(from 1-2 yrs)
5
World class companies
10
Very high level (e.g. Toyota Motors)
30
Japanese Terms
MudaMuraMuri
Any Questions??
Purpose of Kaizen
To identify, reduce and totally eliminate the
3M
Tools 5S (Workplace Management)VSM (Value Stream Mapping) JIT (Just-In-Time)SMED (Single Minute Exchange of Dies)KanbanCellular ManufacturingTPM (total Productive Maintenance.Six SigmaPoka yokeVisual Management (tool for creating
standards)
Any Questions??
Thank You