lean manufacturing tools and

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Lean Manufacturing Tools andTechniques in ProcessIndustry

Presented by,


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Brief Introduction:

The main objective of this paper is to provide a

background on lean manufacturing, present an

overview of manufacturing wastes and introduce

the tools and techniques that are used to

transform a company into a high performing

lean enterprise. Applications have spannedmany sectors including automotive, electronics

and consumer products manufacturing .


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LEAN MANUFACTURIN:

The term ean !anufacturing can be de"ned as a system that utilises

less, in terms of all inputs, to create the same output as those created

by a traditional mass production system while contributing increased

variety for the end customer. !Lean"# is a production practice that

considers the e#penditure of resources for any goal other than the

creation of value for the end customer to be wasteful, and thus a

target for elimination. Proper knowledge of the system and

identi"cation of waste is very much required for its removal.

$ene"ts%

&' (ost reduction. )' $etter quality

*' +emoval of waste. ' $etter service

-' $etter productivity

' Time management.


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/01(+2PT234 35 !31T (3!!34 T6P0 35 7A1T0

&' MURI$ 2t implies overburden. 2n a company the managementassigns workers various job which do not add value to the product such

as carrying heavy weights, moving inventory around . The root causebehind this is the lack of organisation.

*' MURA: 2t refers to unevenness.

%& MU'A$ 2t is a 8apanese word meaning waste and is a key concept of TP1

9Toyota Production 1ystem'. 2t includes seven waste which are as follows%

Trans(ortation$ The "nished product has to be transported from the

manufacturing plant to the customer. 2t stands risk of being damaged, lost or

decayed. Also transportation process is time consuming which does not

increase product value.

In)entory$ 2nventory may represent raw materials, working progress of

manufactured goods. There should be continuous ow of inventory so that

they can be processed to add value.


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*aiting$ 2t may be due to unavailability of raw materials in the

company or due to strike of workers for any reason. 3perators keep

on waiting for a previous operation, a delivery of products to arrive or

just slowly working so as not to highlight that they have run out of

materials.

Unnecessary Motion: The design of workshop is very important.

The workers should not waste time looking around for tools and

necessary equipment;s. !aterials should be properly placed.

+)er,(rocessing$2t is a condition when more work is done on a

piece than what is required by the customer. The goods so

manufactured is considered as waste

+)er,(roduction$3ver%production occurs when more goods are

produced than desired. Additional goods have to be stored in stock

and company has to spend capital on it for its maintenance.

'efects$2f a defect has been spotted than e#tra cost are incurred


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ELIMINATI+N +F *A-TE

After pointing out the various causes of waste it is

very much essential to remove them for survival in

today;s manufacturing world. 3rganisation stress onmanufacturing better quality products with low

manufacturing cost that can be made available to

users in short duration of time. The ne#t set of tools

can be utilised to reduce waste.


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Tools to reduce waste:

.& /ust In Ti0e: 2t utilises a system called the


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4s syste0: 2t refers to workplace organisation where the work place

is organised properly for e@ciency and e?ectiveness. 2t focuses on

arrangement of tools in such a way that frequently used items are

easiest to locate. 7orkspace should be kept neat and clean.

'e)elo(ing (artners and adding )alue to organisation: 0?orts

are made to understand each other which strengthen the team work

in various projects. Teams are trained and developed who assist thecompany when required.

*or5(lace Maintenance: 7orkplace constitutes of various

machinery and one of the most important issues that concerns people

is the machine breakdown on the shop oor. 2f a single machine

breaks, it can bring the entire assembly line or the entire plant to a

hault.


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Total Producti)e Maintenance: 3ne of the main

objectives of TP! is to increase the productivity of plant and

equipment with a modest investment in maintenance. Totaluality management 9T!' and Total Productive !aintenance

9TP!' are considered as the key operational activities of the

quality management system. In order for TPM to 3e e6ecti)e#

the full su((ort of the total 7or5force is required8 Thisshould result in acco0(lishing the goal of TPM8

There are "ve major preventable losses:

&. $reakdown losses caused by the equipment

*. 1et%up and adjustment losses

-. !inor stoppage losses

. 1peed losses

). uality defect and rework losses


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C+NCLU-I+N

2n this paper the most important aspects about lean manufacturing was

presented. 2ts bene"ts can help an industry grow productively.

Co0(anies those 7ho ha)e ado(ted lean 0anufacturing ha)e

lo7ered cost# i0(ro)ed (roducti)ity and also i0(ro)ed quality8

Toyota 7as a3le to greatly reduce lead,ti0e and the cost using

the TP-8This has enabled it to become one of the ten largest companies

in the world. 2t also became the largest car manufacturer in *BBC 8

Achieving such a goal is not easy, continuous improvement has to done

in all segments of an industry to achieve this goal. The (ri0ary idea of

this research is to hel( the (rocess industry to ta5e initiati)es

such as lean 0anufacturing in order to 3eco0e 0ore cost,

e6ecti)e and 0ore e9cient8


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