“LEAN MANUFACTUING-CONCEPT, LIMITATION, APPLICATIONS: AN

OVERVIEW”

Submitted By

Ms. PUNAM NIVRUTTI PATIL

DPGD/OC13/1243

SPECIALIZATION: OPERATIONS

WELINGKAR INSTITUTE OF MANAGEMENT DEVELOPMENT & RESEACH

AUGUST 2015

INTRODUCTION

• Lean manufacturing- A way to eliminate waste & improve efficiency in manufacturing environment.

• Lean was generated from just in time(JIT) Philosophy of continuous & forced problem solving.

• Lean is the fundamental way that many of the world’s best companies do business.

• It is the production of goods using less everything compared to traditional mass production.

FORMS OF WASTE

• Muda- Any form of waste in process

• Muri- Unreasonable burden on people or machines

• Mura- Waste created through unevenness

GOALS

Improve Quality

Reduce total costs

Reduce Time

Zero accidents

Zero inventory

LEAN MANUFACTURING PROCESS

Identify waste Analyze the waste & find

the root cause

Solve the root cause & repeat

the cycle

TOOLS

• 5 S

• Andon

• Bottleneck Analysis

• Continuous flow

• Gemba

• Heijunka

• Hoshin kanri

• Jidoka

• Just In Time

• kaizen

• Kanban

• Key performance indicator

• Overall equipment effectiveness

• PDCA

• Poka Yoke

• Root cause analysis

• SMED

• Takt time

• Total productive maintenance

• Value stream mapping

• Visual factory

Some of important tools

5 S

• Clearing (Seiri)

• 2. Organizing (Seiton)

• 3. Cleaning ( Seiso)

• 4. Standardization (Seiketsu)

• 5. Discipline & Training (Shitsuke)

Just In Time

• The ideal just in time facility would carry zero finished goods and build them only when they are ordered

kaizen

• Kaizen simply means "change for better“

• The Toyota Production System is known for kaizen

KANBAN

• The basic concept of a kanban is a hand

sized card that moves with the product or

material.

• There are two basic classifications of

kanbans; generic and brand.

• Within the two classifications there are

two main types of kanbans; production

kanbans and move kanbans

Total Productive

Maintenance

TPM (Total Productive Maintenance) is a

holistic approach to equipment

maintenance that strives to achieve

perfect production:

No Breakdowns

No Small Stops or Slow Running

No Defects

In addition it values a safe working

environment:

No Accidents

KEY IMPLICATIONS OF LEAN MANUFACURING

Traditional Batch Manufacturing Lean Manufacturing

Orientation Supply driven Customer driven

Planning Orders as pushed through factory based on production plan / forecast

Orders are pulled through factory based on customer / downstream demand

Inventory Buffer of work in progress between each production stage

Little or no wok in progress between each production stage

Handoff of work in process Material after each stage accumulate into work in progress stage areas before being retrieved by next production stage

Material handed of directly from one production stage to next

Production cycle time Longer than actual time Shorter

LIMITATIONS

• Supply Problems • High cost of implementation • Lack of acceptance by employees • Customer dissatisfaction problems • New inefficiencies • Problems in Just In Time (JIT) • Worker frustration • Over focus on waste • Over focus on present • Lack of standard methodology

APPLICATIONS

• In process industries

• In financial service sector

• In emergency department

• In construction industries

• In pharmaceutical industries

• In public

Toyota Production System

TPS has three desired outcomes:

• To provide the customer with the highest quality vehicles, at lowest possible cost, in a timely manner with the shortest possible lead times.

• To provide members with work satisfaction, job security and fair treatment.

• It gives the company flexibility to respond to the market, achieve profit through cost reduction activities and long-term prosperity.

CONCLUSION

Lean manufacturing is:

“A systematic approach to identifying and eliminating waste (non-value added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection”.