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!