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Lean Manufacturing Concepts and Tools and
Quality Management
By Hristina Koycheva
What is Lean?
Lean is an Operational Excellence Strategy that enable you to change for the better- in fact the Japanese often use “Kaizen” which use by lean practitioners to describe incremental improvements ;
What is Lean?
Persistent process in elimination of waste – MUDA – describes any activity that’s done, but add no real value to the product or service.
What is Lean?
Respect for people
High Quality and Stable Processes
Where?
At all level there is a strong desire to be better;
A culture of lean is visibly prioritised and practice from the top to the bottom of the workforce;
The key is understanding the customer and delivering his requirements;
How? Improves business performance using simple
practical tools and techniques to enhance quality, cost, delivery and people contribution;
Exposes the wastes in the system; People need to change their long standing work
practices and ideas; Senior management need to drive lean
principles forward with total commitment to its success;
Not a “bolt on” technique, more a way of life leading to a total change in culture.
Short History 1913: Henry Ford
(Start of mass manufacturing with themoving line)
1938 JIT Born
Short History
1950: Eiji Toyoda brings the ideas of continuous movingline in Japan
Short History 1960: Toyota
production System, main principles of lean manufacturing
1991: Lean Management
Main Principals
Identify the customer Map the flow Make a product or service flow Create polls based on customer
demands Continually find ways to improve
Lean Tools
Assessment and planning- fundamentals and understanding where we are today and creating and design for tomorrow.
Plan, Do, Check, Act
Lean Tools
5 “S”
Visual control
Standardize work
Total productive maintenance
Select the key Reduce cost of
production
Increase customer satisfaction
Improve quality
Select the
key
Map Process
Eliminate Waste
Make Process Flow
Establish Customer
Poll
What Is Waste? Waste of overproduction (largest
waste) Waste of time on hand (waiting) Waste of transportation Waste of processing itself Waste of stock at hand Waste of movement Waste of making defective products
Lean ThinkingKey Principals of Lean Thinking
Value - what customers are willing to pay for;
Value Stream – the steps are delivered value;
Flow – organizing Value Stream to be continuous;
Polls – responding to downstream customer demand;
Perfection – relentless continuous improvement (culture);
Lean Thinking, Womack and Jones,1996
Conclusion
Lean 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.”
Production System
Two pillars:
Jidoka
Just-in-time
What is Jidoka? “Jidoka” means
autonomous. The responsibility of each associate to deliver Quality to the customers.- Intense Motivation Training;- Explained Information;
Just-in-time Aims of zero
inventory;
Parts are not kept in warehouse;
Parts arrive when needed;
Quality system Quality means
compliance with specifications- no less, no more;
No need for inspections!
Quality Assurance When we focused
on this we will consistently deliver what the customer expects;
Trust raises everyone’s commitment
Thank you!
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