Lean Manufacturing

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

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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!”

• Set in Order—Identify the best location for remaining items and label them. “A place for everything & everything in its place”.

• 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.

• Standardize—Create the rules for maintaining and controlling the first 3 S’s. Use visual controls.

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

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COST SAVINGS

Before 5S

After 5S

After 5S

After 5S

Comparison of Traditional vs. Lean Traditional

Lean

• Complex • Forecast Driven • Excessive

• Simple and

Inventory

• Speed Up ValueAdded Work

• Large Batch Production

• Long Lead Time

Visual

• Demand Driven • Inventory as Needed

• Reduce NonValue-Added

• Small Lot Size • Minimal Lead

THANK YOU