lean process and production

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Lean Production Done by: Ravina Kuttikar Roll No: 1331 Goa University

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Lean Production can be defined as an integrated set of activities designed to achieve high-volume production using minimal inventories (raw materials, work in process, and finished goods). The Toyota Production System All work shall be highly specified as to content, sequence, timing, and outcome Every customer-supplier connection must be direct, and there must be an unambiguous yes-or-no way to send requests and receive responses The pathway for every product and service must be simple and direct Any improvement must be made in accordance with the scientific method, under the guidance of a teacher, at the lowest possible level in the organization

TRANSCRIPT

Page 1: Lean Process and Production

Lean ProductionDone by: Ravina

KuttikarRoll No: 1331

Goa University

Page 2: Lean Process and Production

Lean Production Lean Production can be defined as an integrated set of activities designed to achieve high-volume production using minimal inventories (raw materials, work in process, and finished goods)

Lean Production also involves the elimination of waste in production effort

Lean Production also involves the timing of production resources (i.e., parts arrive at the next workstation “just in time”)

Page 3: Lean Process and Production

Features of Lean Production• Management philosophy• “Pull” system though the plant

WHAT IT IS

• Employee participation• Industrial engineering/basics• Continuing improvement• Total quality control• Small lot sizes

WHAT IT REQUIRES

• Attacks waste• Exposes problems and bottlenecks• Achieves streamlined production

WHAT IT DOES

• Stable environment

WHAT IT ASSUMES

Page 4: Lean Process and Production

Lean Six Sigma Incorporates the Key Methods, Tools, and Techniques of Its Predecessors

Page 5: Lean Process and Production

The Toyota Production System

Based on two philosophies:1. Elimination of waste

2. Respect for people

Page 6: Lean Process and Production

Elimination of Waste1. Focused factory networks2. Group technology3. Quality at the source4. JIT production5. Uniform plant loading6. Kanban production control

system7. Minimized setup times

Page 7: Lean Process and Production

Respect for PeopleLevel payrolls

Cooperative employee unions

Subcontractor networks

Bottom-round management style

Quality circles (Small Group Involvement Activities or SGIA’s)

Page 8: Lean Process and Production

Toyota Production System’s Four Rules1. All work shall be highly specified as to content, sequence, timing, and outcome

2. Every customer-supplier connection must be direct, and there must be an unambiguous yes-or-no way to send requests and receive responses

3. The pathway for every product and service must be simple and direct

4. Any improvement must be made in accordance with the scientific method, under the guidance of a teacher, at the lowest possible level in the organization

Page 9: Lean Process and Production

Lean Implementation Requirements: Design Flow ProcessLink operationsBalance workstation capacities Redesign layout for flow Emphasize preventive maintenance Reduce lot sizes Reduce setup/changeover time

Page 10: Lean Process and Production

Lean Implementation Requirements: Total Quality ControlWorker responsibility

Measure SQC

Enforce compliance

Fail-safe methods

Automatic inspection

Page 11: Lean Process and Production

Lean Implementation Requirements: Stabilize Schedule Level Schedule Underutilized Capacity Establish freeze windows

Page 12: Lean Process and Production

Lean Implementation Requirements: Kanban-PullDemand pull

Back flush

Reduce lot sizes

Page 13: Lean Process and Production

Lean Implementation Requirements: Work with VendorsReduce lead times

Frequent deliveries

Project usage requirements

Quality expectations

Page 14: Lean Process and Production

Lean Implementation Requirements: Reduce Inventory MoreLook for other areas

Stores

Transit

Carousels

Conveyors

Page 15: Lean Process and Production

Lean Implementation Requirements: Improve Product DesignStandard product configuration

Standardize and reduce number of parts

Process design with product design

Quality expectations

Page 16: Lean Process and Production

Lean in Services (Examples)Organize Problem-Solving Groups

Upgrade Housekeeping

Upgrade Quality

Clarify Process Flows

Revise Equipment and Process Technologies

Page 17: Lean Process and Production

Lean in Services (Examples)Level the Facility Load

Eliminate Unnecessary Activities

Reorganize Physical Configuration

Introduce Demand-Pull Scheduling

Develop Supplier Networks

Page 18: Lean Process and Production

Thank You...