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LEAN SYSTEM

• Presented By:-• Siddhant Chavan • 14106A1003

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• Engineer Taiichi Ohno. (After World War II.)

• In simple terms, lean means creating more value for customers with fewer resources.

• The ultimate goal is to provide perfect value to the customer through a perfect value creation process that has zero waste.

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INTRODUCTION

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• Ohno vs. Ford

• Ford - Maintaining resources in anticipation of what might be required for future manufacturing.

• Ohno - focus on eliminating waste and empowering workers, reduced inventory and improved productivity.

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PHILOSOPHY

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WASTE ELIMINATION

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BASIC ELEMENT OF LEAN

• JIT

• Kanban

• 5S’s

• Jidoka

• Kaizan

• TPM

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• Concept - Activity should not take place unless there is need for it.

• Inventory should not be brought into the system until it is required for making the final product.

• Purchase raw materials JIT to be used for production.

Produce & deliver finished goods JIT to be sold.

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JUST IN TIME

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KANBAN• Designates a pull production means of communicating need for

product or service.

• Means to communicate between operations in different locations.

(Intended to communicate a change in demand or supply)

• Generally used to trigger the movement of material

to or though a process.

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JIDOKA• Transferring human intelligence to semi-automated or

automated machinery.

• Machines, not people detects production defects and immediately stops themselves.

• Such a stop is signaled via an ANDON signal.

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5S’s

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KAIZEN• Kai – Change, Zen – Good (for the better)

• Continuous improvement - constantly introducing small

incremental changes.

• Everyday – Everybody – Everywhere Improvement

• Existing operation

always has a room

for improvement.

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RESISTANCE TO IMPLEMENT KAIZEN

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TPM• Total – Overall operational efficiency of equipment

Total production system

Participation of all employees

• Productive – No defects

No breakdowns

No accidents

• Maintenance – Proactive & preventative maintenance

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BENEFITS OF LEAN MFG.1. Waste reduction by 80%

2. Reduction of production cost by 50%

3. Reduction in manufacturing cycle time and labor requirement by 50%

4. Inventory reduction by 80% maintaining the same level of customer service.

5. Higher quality and profits.

6. Increase in capacity by 50%

7. More strategic focus.

8. Increase shipping and billing frequencies resulting increase in cash flow.

waste reduction

production cost reduction

manufacturing cycle time reduction

labor reduction

inventory reduction

production capacity increase

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