Lean Manufacturing & Philosophy

S G Deshmukh

Motivation..

Taichi Ohno (1912-1990)

Taiichi Ohno was a

Japanese industrial

engineer and businessman.

He is considered to be the

father of the Toyota

Production System, which

became Lean

Manufacturing in the U.S.

He devised the seven

wastes as part of this

system.

Lean Manufacturing Definition

“A philosophy of production that emphasizes the minimization of the amount of all the resources (including time) used in the various activities of the enterprise. It involves identifying and eliminating non­value­adding activities in design, production, supply chain management, and dealing with the customers. . .”

–– APICSAPICS

Youtube : Toyota Global Story (20. minutes)

• https://www.youtube.com/watch?v=T5zcCk-uF3g

Lean Enterprise Definition

“An enterprise with a focus on waste elimination and the customer’s needs in all parts of its operations, manufacturing, and administration. Emphasis is given to lean structures and processes, flexibility of response, and methods and techniques to continually seize new opportunities as they arise.”

– APICS

Lean Thinking Principles

1. Accurately specify the value of the products or services (applies to both factory and office areas, not just to manufacturing).

2. Identify the value stream for each product or service and remove wasted actions

3. Make the product or service value flow without interruptions.

4. Let customers pull products or services from the producer.

5. Pursue perfection and continuously improve.

Lean Manufacturing Characteristics

• Focus is on the improvement of resource utilization:– Equipment setup time reduced– Scheduled machine maintenance– Orderly, clean workplace

– Pull production being used

– JIT inventory control

– Factory layout in workcell arrangement by products

– Active error elimination– Improved quality, etc.

Importance of Waste Elimination

Lean deals with the elimination or reduction of many types of non value­ added activities, often referred to as wasteThe driving force for waste elimination is improved value in

the products and services customers buy.

Anything that DOES NOT add VALUE is waste

Lean Manufacturing System (LMS)

The Lean Manufacturing system has been described as one,

which seeks to eliminate unnecessary wasteful processes,

to align processes in a continuous flow to use resources in order to solve problems in a

never­ending process.

Lean Manufacturing System(Some more definitions)

More and more with less and less-less human effort, less equipment, less time and less space-while coming closer to providing customers with exactly what they want .

A comprehensive process improvement methodology that streamlines operations from concept to customer delivery, reduces inventory, speeds production, reduces cost and improves quality and response time using state of art Industrial Engineering tools.

NIST perspective on Lean

• A systematic approach in identifying and eliminating waste through continuous improvement, flows the product at the pull of the customer in pursuit of perfection

Basic tenets of Lean

• Understand customer value

• Appreciate Pull system

• Deploy Value stream mapping

• Follow the principle of “Flow”

• Aim at perfection

Comment.

• The perfection is basically with an understanding that : There is no end to reduce time, cost , space, mistakes and efforts” Once we manage these, we get closer to Lean

Lean Organization Characteristics

• Strong leadership committed to all lean principles.• Effective production & delivery of products and services

based on customer demand.• An exceptionally safe orderly and clean work

environment• A commitment to design & build quality in to products,

services & supporting processes.• A team work culture where every one is empowered to

make and act upon decisions.• Appropriate and active use of visual management

tools.• Continuous improvement is an obvious way of life

throughout the organization• A strategy embracing Lean principles

Steps of Lean Manufacturing System Implementation

• Step 1: Specify Value: Define value in terms of a specific product, which meets the customer's needs at a specific price and at a specific time.

• Step 2: Map Identify the value stream: The set of all specific actions required to bring a specific product through the three critical management tasks of any business: the problem-solving task, the information management task, and the physical transformation task. Create a map of the Current State and the Future State of the value stream. Identify & categorize waste in the Current State, & eliminate it!

• Step 3: Flow: Make the remaining steps in the value stream flow. Eliminate functional barriers and develop a product-focused organization that dramatically improves lead-time.

• Step 4: Pull: Let the customer pull products as needed, eliminating the need for a sales forecast.

• Step 5: Perfection: There is no end to the process of reducing effort, time, space, cost, and mistakes. Return to the first step and begin the next lean transformation.

Benefits of Implementing Lean Manufacturing System

a. Elimination of wasteb. Lower costc. Higher qualityd. Shorter throughpute. More flexibility through flexible production linesf. Customer satisfactiong. Less inventoryh. Speedy execution of ordersi. A force of dedicated, motivated, multi-skilled

workmenj. Optimal resourcesk. Increased productivityl. Perfect first time qualitym. Continuous improvementn. Improved confidence and mutual trust at every

level of organization

Seven Popular Wastes from TPS

1. Defects

2. Overproduction

3. Transportation

4. Waiting

5. Inventories

6. Motion

7. Processing

Youtube video on Seven Wastes• https://www.youtube.com/watch?

v=mAYMcSUDcX0

Getting Started..1..

• Identify potential companies interested in LMS (auto component is one of them (Gurgaon, Noida))

• Identify imperatives for these companies to get started

• Sensitize the company personnel• Understand the existing system and ways of

migrating to LMS

Getting Started..2..

• Learn from best practices of each other (German and Indian companies)

• Document these practices Train and Educate

• Prepare repository of knowledge base in LMS

• Exchange notes between stakeholders

Remarks..

• According to Ohno, Lean Philosophy is directed to

• :Maximize the work effort of a company’s number 1 resource, namely “people”.

Youtube on “ Toyota Lean Manufacturing System” (15 Minutes)

• https://www.youtube.com/watch?v=8KJaEOiHxNw

Lean Manufacturing at Boeing

• https://www.youtube.com/watch?v=9_9WyiPhoHA

Remark..

• Lean may not operate where customer demand is unstable, unpredictable

Lean on Facebook !

• https://www.facebook.com/pages/Lean-On-Discovering-Lean-Manufacturing/1531276217158436

https://www.facebook.com/LeanMentality

Thanks