What is Lean Production2

7/29/2019 What is Lean Production2

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LEAN PRODUCTION

PRESENTED BY,

NITHIN P

S6 TDE

ROLL

NO:30


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WHAT IS LEAN PRODUCTION?

It is a team-based approach ofmanufacturing focused on identifying andeliminating waste through continuous

improvement


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Basic Elements of LeanManufacturing

Pull system

Lead time reduction

Continuous improvements


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Applications of Lean Production

Lean techniques are also applicable inservice-oriented industry and serviceenvironment. The techniques for analyzing

systems, identifying and reducing waste,and focusing on the customer are applicablein any system, and in any industry.


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LEAN BUILDING BLOCKS


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AUTONOMATION

to prevent mass-production ofdefective work in machines or

product lines.


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LOAD LEVELING

It isa production scheduling / load levelingtool, essentially to distribute kanban cardsin an efficient manner.


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TPM

goal of TPM is to minimize downtime due tomaintenance, and maximize machineuptime.


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POKA YOKE

system to create devices that can discoverdefectives without the workers


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5 S

This tool is a systematic methodfor organizing and standardizing

the work place SORT

STRAIGHTEN

SWEEP

STANDARDISE SELF DISCIPLINE


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The 7 Wastes To Be Eliminated

Overproduction - producing over customer requirements,producing unnecessary materials

Waiting- time delays, idle time

Transportation - multiple handling, delay in materialshandling, unnecessary handling

Inventory - holding or purchasing unnecessary rawmaterials, work in process, and finished goods

Motion - actions of people or equipment that do not addvalue to the product

Over-processing - unnecessary steps or work elements

Defective units - production of a part that requires rework.


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Characteristics

Integrated single piece continuous workflow

Just-in-time processing: a part moves to aproduction operation, is processed immediately,

and moves immediately to the next operation Production is based on orders rather than

forecasts.


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KEY

FEATURES


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Employee Involvement AndEmpowerment

- organizing workers by forming teams

and giving them training and

responsibility to do many specializedtasks, for housekeeping, quality

inspection, minor equipment repair and

rework; allowing also them time tomeet to discuss problems and find ways

to improve the process


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Continuous EquipmentMaintenance

- as pull production reduces inventories,

equipment breakdowns must also be

reduced; thus empowered operators areassigned primary responsibility for basic

maintenance since they are in the best

position do detect signs of malfunction


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Multi-Skilled Workforce

- In order to have smoothed production,it is necessary that the worker be skilled

in a number of functions


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SHORT SET UP TIME

Through constant efforts by use of qualitycircles, set up times have been reduced


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BENEFITS

Lead Time (Cycle Time) reduced by90%

Productivity increased by 50%

Work-In-Process Inventory reduced by

80%Quality improved by 80%

Space Utilization reduced by 75%


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CONCLUSION

In the era of globalization, all theorganizations try to improve productivityand quality using all the industrial

engineering tools. Lean manufacturing is adominant tool which is proven globally asone of the best tool available to improve

overall operating efficiency.


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THANKYOU

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What is Lean Production2