Professional Documents
Culture Documents
GROUP H :
VISHAL PANDITA (11MI3EP19)
3MS OF LEAN
Lean manufacturing is a Japanese method focused on 3 Ms.
muda waste
mura inconsistency
muri - unreasonableness
MUDA - WASTE
Anything that does not add value to the product can be defined as waste The implementation of lean manufacturing techniques requires that all the wastes are identified and eliminated from the system
TYPES OF WASTE
Waste of inventory (space and time)
Overproduction
Over Processing
Processing beyond the standard required by the customer.
1 7
Inventory
Raw material, work in progress or finished goods which is not having value added to it.
Rework
6 5 4
3
Motion
Waiting
People or parts that wait for a work cycle to be completed.
Transportation
MURA - INCONSISTENCY
Inconsistency is a problem
engineering to management.
MURI - UNREASONABLENESS
An example of being unreasonable is by blaming someone for problems rather than looking at resolution of problems. Management creates a non-blaming culture where : Problems are recognized as opportunities Its okay to make legitimate mistakes People are not problems, they are problem solvers Emphasis is placed on finding solutions instead of who did it
Customer Order
Waste Time
Product Shipment
Lean Manufacturing
Customer Order
Waste
Time (Shorter)
Product Shipment
5 SS OF LEAN
In implementing Lean, 5 Ss are frequently used to assist in the organization of manufacturing. The 5 Ss are from Japanese and are :
Seiri sort, necessary items Seiton - stabilize, efficient placement Seison - shine, cleanliness Seiketsu - standardize, continuous improvement Shitsuke - sustain, discipline
IMPLEMENTATION STAGE
The following activities relating to lean manufacturing are performed : Execution of the project implementation plan Design and manufacture of special tools and materials handling equipment Outsourcing of capex (if needed) Training of relevant staff
Thank you
Specify value :
Specify value from the standpoint of the end customer by product family.
Identify the value stream : Identify all the steps in the value stream for each product family, eliminating whenever possible those steps that do not create value.
Create flow :
Make the value-creating steps occur in tight sequence so the product will flow smoothly toward the customer.
Let the customer pull product through the value stream: Make only what the customer has ordered. Seek perfection : As value is specified, value streams are identified, wasted steps are removed, and flow and pull are introduced, begin the process again and continue it until a state of perfection is reached in which perfect value is created with no waste.
A fundamental principle of lean manufacturing is demand-based flow manufacturing. In this type of production setting, inventory is only pulled through each production centre when it is needed to meet a customers order.
The benefits of this goal include decreased cycle time less inventory increased productivity increased capital equipment utilization
There is always room for improvement The core of lean is founded on the concept of continuous product and process improvement and the elimination of non-value added activities. The Value adding activities are simply only those things the customer is willing to pay for, everything else is waste, and should be eliminated, simplified, reduced, or integrated. Improving the flow of material through new ideal system layouts at the customer's required rate would reduce waste in material movement and inventory. Continuously improve A continuous improvement mindset is essential to reach a company's goals. The term "continuous improvement" means incremental improvement of products, processes, or services over time, with the goal of reducing waste to improve workplace functionality, customer service, or product performance.
Improve quality:
In order to stay competitive in todays marketplace, a company must understand its customers' wants and needs and design processes to meet their expectations and requirements.
Eliminate waste: Waste is any activity that consumes time, resources, or space but does not add any value to the product or service.
Reduce time: Reducing the time it takes to finish an activity from start to finish is one of the most effective ways to eliminate waste and lower costs.
Reduce total costs: To minimize cost, a company must produce only to customer demand. Overproduction increases a companys inventory costs due to storage needs.