lean-manufacturing
Content
LEAN MANUFACTURING
Presented By:
Gaurav Kumar Manish Gupta Pavan Ghargi
Lean Manufacturing Is:
• It is focusing on the ELIMINATION of WASTE (non-value-added activities) through CONTINUOUS IMPROVEMENT!
Lean Manufacturing
3 Pronged Approach
What makes a manufacturing system lean? – the 3 M’s of lean
• muda – waste • mura - inconsistency • muri - unreasonableness
Value stream mapping
• Follow a “product” or “service” from beginning to end • Draw a visual representation of every process in the material & information flow
Value Stream Mapping
Helps us see where value is created, and where waste exists:
• A visual approach, by “product family”
• Shows flow of both material & information • Helps us see which specific Lean tools can be used to improve flow and eliminate waste • Two maps will be made: Present State (“how it is”) & Future State (“how it should be”)
Value Added vs NonValue Added
• Value added: Transforms raw material and information into products or services to be marketed • Non-value added (waste): Consumes resources but does not contribute directly to the product or service to be marketed
7 Deadly Wastes
What is 5S?
• Represents 5 disciplines for maintaining a visual workplace 1)Sort 2)Set in Order (Stabilize) 3)Shine 4)Standardize 5)Sustain
Title
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Elements of a 5S Program
• Sort—Perform “Sort Through and Sort Out,” - red tag
all unneeded items and move them out to an established “quarantine” area for disposition within a predetermined time. “When in doubt, move it out!” items and label them. “A place for everything & everything in its place”.
• Set in Order—Identify the best location for remaining • Sweep (Systematic Cleaning)—Clean everything,
inside and out. Use visual sweeps to ensure everything is where it should be and that junk is not accumulating. controlling the first 3 S’s. Use visual controls.
• Standardize—Create the rules for maintaining and
Who wants what…
Cash !!
Value !!
Customer
Low Cost High Quality Availability
Your Company
Profit Repeat Business Growth
Potential Benefits of Lean
• • • • • 90% reduction of production times 50% increase in productivity 80% quality improvement 75% improvement in space utilization 85% reduction of "work in progress" (stuff waiting to be finished) • And reduction of material waste
=
COST SAVINGS
Before 5S
After 5S
After 5S
After 5S
Comparison of Traditional vs. Lean
Traditional
• Complex • Forecast Driven • Excessive
Inventory
Lean
• Simple and
Visual
• Speed Up ValueAdded Work Production
• Demand Driven • Inventory as
Needed
• Large Batch • Long Lead Time
• Reduce NonValue-Added
• Small Lot Size • Minimal Lead
THANK YOU
Presented By:
Gaurav Kumar Manish Gupta Pavan Ghargi
Lean Manufacturing Is:
• It is focusing on the ELIMINATION of WASTE (non-value-added activities) through CONTINUOUS IMPROVEMENT!
Lean Manufacturing
3 Pronged Approach
What makes a manufacturing system lean? – the 3 M’s of lean
• muda – waste • mura - inconsistency • muri - unreasonableness
Value stream mapping
• Follow a “product” or “service” from beginning to end • Draw a visual representation of every process in the material & information flow
Value Stream Mapping
Helps us see where value is created, and where waste exists:
• A visual approach, by “product family”
• Shows flow of both material & information • Helps us see which specific Lean tools can be used to improve flow and eliminate waste • Two maps will be made: Present State (“how it is”) & Future State (“how it should be”)
Value Added vs NonValue Added
• Value added: Transforms raw material and information into products or services to be marketed • Non-value added (waste): Consumes resources but does not contribute directly to the product or service to be marketed
7 Deadly Wastes
What is 5S?
• Represents 5 disciplines for maintaining a visual workplace 1)Sort 2)Set in Order (Stabilize) 3)Shine 4)Standardize 5)Sustain
Title
• Lorem ipsum dolor sit amet, consectetuer adipiscing elit. Vivamus et magna. Fusce sed sem sed magna suscipit egestas. • Lorem ipsum dolor sit amet, consectetuer adipiscing elit. Vivamus et magna. Fusce sed sem sed magna suscipit egestas.
Elements of a 5S Program
• Sort—Perform “Sort Through and Sort Out,” - red tag
all unneeded items and move them out to an established “quarantine” area for disposition within a predetermined time. “When in doubt, move it out!” items and label them. “A place for everything & everything in its place”.
• Set in Order—Identify the best location for remaining • Sweep (Systematic Cleaning)—Clean everything,
inside and out. Use visual sweeps to ensure everything is where it should be and that junk is not accumulating. controlling the first 3 S’s. Use visual controls.
• Standardize—Create the rules for maintaining and
Who wants what…
Cash !!
Value !!
Customer
Low Cost High Quality Availability
Your Company
Profit Repeat Business Growth
Potential Benefits of Lean
• • • • • 90% reduction of production times 50% increase in productivity 80% quality improvement 75% improvement in space utilization 85% reduction of "work in progress" (stuff waiting to be finished) • And reduction of material waste
=
COST SAVINGS
Before 5S
After 5S
After 5S
After 5S
Comparison of Traditional vs. Lean
Traditional
• Complex • Forecast Driven • Excessive
Inventory
Lean
• Simple and
Visual
• Speed Up ValueAdded Work Production
• Demand Driven • Inventory as
Needed
• Large Batch • Long Lead Time
• Reduce NonValue-Added
• Small Lot Size • Minimal Lead
THANK YOU
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