Lps

What is “Lean Manufacturing?” • Lean manufacturing is aimed at elimination of waste • Organize processes to add value to the customer • Deliver goods “just-in-time” • Service organizations also using lean

Basic Lean Principles • Add nothing but value – Eliminate “muda” – waste

• Do it right the first time • People doing the work add value – Team oriented

• Deliver on demand – “Pull” instead of push

History of Lean • “The Machine That Changed the World” • Toyota auto manufacturing • “Value chain”

Waste Categories • • • • • • • •

Overproducing Inventory Waiting Extra Processing Correction Excess Motion Transportation Underutilized People

OVERPRODUCIN G To producer sooner, faster or in Greater quantites than customer demand.

INVENTOR Y

RAW MATERIAL WORK IN PROGRESS OR FINISHED GOODS WHICH IS NOT HAVING VALUE ADDED TO IT.

INVENTOR Y

WAITING PEPOLE OR PARTS THAT WAIT FOR A WORK CYCLE TO BE COMPLETED.

WAITING

TRANSPORTATIO N

UNNECESSARY MOVEMENT OF PEOPLE ,PARTS OR MACHINES WITHIN A PROCESS.

REWORK Non right first time ,Repetition or correction of a process.

OVER PROCESSING

Processing beyond the standard required by the customer.

8th WASTE Potential of people

Flow Process Charts for Data Recording This chart uses

This chart is of 3 types:

circles for operations

 Man – Activities of operator

arrows for transports squares for inspections  triangles for storage letter D for delays.

 machine - Manner in which the equipment is used

Before Layout Revision Sl. No . 1

 Material - the changes the material undergoes in location or condition Process

Operation

M achine

Storage

From In trolley

2

Coining

Press

Sl. No.

Operation

Machine

3

Storage + Relief Plug Assy.

Trolley

1

Storage

In trolley

4

Ball Pressing

Press

Coining

Press

Storage

On the Machine

2

5 6

Leak Check

Air Gauge

3

Bearing Pressing

Press

7

Storage

Table

4

Ball Pressing

Press

8

Poppet assembly

Table

9

Bearing Pressing

Press

10

Storage

Table

11

Thrust washer Assy.

Poka-Yoke

12

Storage

--

Total

After Layout Revision

5 6

Leak Check& Poppet Assy. Thrust washer Assy.

Total 6

6

0

1

Process

Table PokaYoke 1

5

4

Vertical lines connect these symbols in the sequence they are performed.

0

0

0

BEFORE Before Layout Revision Sl. No . 1

Operation

M achine

Storage

From In trolley

2

Coining

Press

3

Storage + Relief Plug Assy.

Trolley

4

Ball Pressing

Press

5

Storage

On the M achine

6

Leak Check

Air Gauge

7

Storage

Table

8

Poppet assembly

Table

9

Bearing Pressing

Press

10

Storage

Table

11

Thrust washer Assy.

Poka-Yoke

12

Storage

--

Total

Process

Storage Process Inspection Waiting -

6

storage operation transportation

6

0

1

4

inspection waiting

6 6 1 4

AFTER After Layout Revision Sl. No.

Operation

Machine

1

Storage

In trolley

2

Coining

Press

3

Bearing Pressing

Press

4

Ball Pressing

Press

5 6

Leak Check& Poppet Assy. Thrust washer Assy.

Total

Storage - 1 Process - 5

Process

Table PokaYoke 1

5

0

0

0