Lean System Presentation

What is Lean Manufacturing ? Lean Manufacturing is a High velocity order-to-delivery process that many manufacturers have successfully used to improve their overall business performance. Order-to-delivery, receiving orders from customer and producing the demand and on time delivery to the customer. In the Lean Environment, pull the inventory and allow it to flow only when there is a need to satisfy the customer requirement.

Why do we need Lean Manufacturing ? React quickly to changes in customer demand With minimum inventory. It create a lean supply chain by streamlining the Business and production processes to  Significantly reduce Lead time  Decrease inventories  Lower costs  Increase customer service Gaining of market share

Example : Before Lean Thinking The manufacturers are really losing money in the following area. 8 wastes of process created. 1) Over production 2) Defects & rework 3) Unwanted movement 4) Transportation 5) Excessive inventory 6) Over processing 7) Waiting 8) Unutilized man power ( Employee creativity)

Example : Before Lean Thinking An auto component company adopted the following process Vendor 1 RM

M1

M2

Vendor

2

Vendor

3

Vendor

4

M3 Customer

M5

M4

M1 – Duplex Milling , M2 – Drilling SPM, M3 – Boring SPM M4 – Pressing (Bronze bush), M5 - Reaming

Example : Before Lean Thinking Present process status : 1) The Drilling SPM & Boring SPM were not provided Capable process and required quality level. Hence those operations were sent to different Vendors for machining. 1) Rework done for defective component from the 2 SPM’s. 1) Bronze bush was reamed after press fitting into the part. ( which was really not required by the customer). The forth coming are the wastes produced by their discrete manufacturing

Example : Before Lean Thinking 1) Over production : Due to imbalance cycle times & uncertainties Led them towards producing more than required Quantity. They were pushing rather than applying pull. 1) Defects & Rework : The process was not mistake proofed and allowed deviations to quality requirements. Therefore reworked the defects wherever possible.

Example : Before Lean Thinking 1) Unwanted movement : Long man & material movement between machines due to discrete manufacturing process.

1) Transportation : To and fro from various vendors ( people, material & information).

Example : Before Lean Thinking 1) Excessive inventory : Maintained as Raw materials, WIP ( work in progress) in each vendor & in lines semi-finished & Finished components. 1) Over processing : Performing operations that were actually not Necessary.( Example : - Reaming operation)

Example : Before Lean Thinking 1) Waiting : Partially finished goods always waiting for Instructions or transport to be moved. ( Processing, rework, Inspection or movement) The concept of Takt time or balanced cycle Was not used.

So they decided to correct the process & lean thinking adopted.

Example : Before Lean Thinking The following are the main obstacles to lean production 1)

Discrete manufacturing

2)

Scattered process layout

3) Not addressing flow 4) Allowing problems remain hidden 5) Perception of problem is only size variation 6) Imbalanced cycle times 7) Absence of pull and dominance of push 8) Compromise in quality 9) Non acceptance of change

Example : After Lean Thinking They designed new SPM for both drilling & boring.

From RM Duplex milling Drilling & Boring SPM

To customer Pressing bush

Example : After Lean Thinking The benefits achieved after lean production. 1)

Doubling the production

2)

Combined two different operations

3)

Eliminated one reaming operation ( Over processing)

4)

Elimination of Inventory

5)

Elimination of Transport movement

6)

Reduced material movement

7)

Reduced through put time

8)

Controlled process capability

9)

Guarantee both in quality

10) Balanced cycle time 11) Manufacturing cost reduced 12) Back to business 13) Multi machine operation skill developed.

Why aren’t there more successes in Lean Manufacturing ? The reasons are  Less integration in daily managerial behavior  Lack of learning / a mixed bag of learning  Improper Leadership  Existing culture  No team work

Five pillars of Team Work Status & EGO

INATTENTION OF RESULTS AVOIDANCE OF ACCOUNTABILITY

Ambiguity Ambiguity Artificial Harmony

Invulnerability

Clear result: winning Low standards

LACK OF COMMITMENT

Clarity

FEAR OF CONFLICTS

Pasionate dedbates Trust one another

ABSENCE OF TRUST

Results

Accountability

Commitment

Conflict

Trust

Five styles of responding to conflict High

DIRECTING

CO-OPERATING

Focus on Task : High Focus on relationship : Low

Focus on Task : High Focus on relationship : High

I WIN / YOU LOSE

I WIN / YOU WIN “ My reference is … And please tell me yours”

“ We are doing it my way…”

Focus on Task

COMPROMISING

Agenda

Focus on Task : Medium Focus on relationship : Medium I WIN some / YOU WIN some “ I’ii meet you …”

AVOIDING

HARMONISING

Focus on Task : Low Focus on relationship : Low I LOSE / YOU LOSE I LOSE / YOU LOSE

Low

Focus on Task : Low Focus on relationship : High I LOSE / YOU WIN “ Whatever you want is fine with me…”

Relation ship Focus on Relationship

High

Some Interesting saying on Team work “ Team work means Co-operation,Collaboration, Joint effort and Solidarity”. “ Goals must be set in concrete, while plans Made in sand”.

Swami Sukhabodhananda says “ Commitment is the language of the wise; Complaint is that of fools”. “ The greatest strength comes from the energy Of commitment that brings excellence in all Walks of life”.

Some Interesting saying on Lean “ No dream or vision can be achieved without actions”.

“ As you think, so you reap”.

“ Your tomorrow's results depend on your today’s thinking

“ Innovation is everybody’s job” says Gary Hamel but “ the engine at the top has to work to get it going”.

GLOSSARY Magazine : “ Modern Machine tools” Edition – Jan’2007

Presentation compiled by T.RANGANATHAN Presentation on 14.05.2007