LEAN MANUFACTURING

PREPARED BY: Group # 5 DEEPTI SHARMA SHREYA SUNIL SINGH SUMIT AGARWAL HIMANSHU YADAV SAURABH SRIVASTAVA

Agenda
1. 2. 3. 4. 5. What is Lean ? Seven Principles of Lean. Just In Time(Concept). Sources of Wastage. Conclusions.

What is Lean?
Lean means creating more value for customers with fewer resources. ORIGIN Lean Manufacturing is sometimes called the Toyota Production System (TPS) because Toyota Motor Companys Eiji Toyoda and Taiichui Ohno are given credit for its approach and innovations.

Seven Principles of Lean

1. 2. 3. 4. 5. 6. 7. Over-Production Waiting Transportation Inventory Motion Over-processing Defective units

1. Over Production Producing over customer requirements, producing unnecessary materials / products. 2. Waiting Time delays, idle time (time during which value is not added to the product). 3. Transportation Multiple handling, delay in materials handling, unnecessary handling.

4. Inventory Holding or purchasing unnecessary raw materials, work in process, and finished goods. 5. Motion Actions of people or equipment that do not add value to the product. 6. Over-processing Unnecessary steps or work elements / procedures (non added value work). 7. Defective units Production of a part that is scrapped or requires rework.

Concept Used in Lean

JIT (just in time):- It means producing the necessary items in necessary quantities at the necessary time. Benefits of JIT: 1. Reduced operating cost 2. Greater performance 3. Higher quality 4. Improved delivery 5. Increased flexibility and innovativeness 6. Shortened lead time 7. Reduced inventory

Sources of Wastage
Inventory-related waste:

Manufacturing Organization Waiting for material to work on Stock Verification Counting the number of parts Temporary storage Parts shortage

Service Organization Duplication of work Excessive paper work Incomplete information leading to pending decision Overflowing in baskets

Waste Due to process:

Manufacturing Organization Defects and rework Machine breakdowns Watching the machine run

Service Organization Payments not mad on time Wrong service delivery Customer order taking too long time Proposal not completed on time

Waste Due to planning:

Manufacturing Organization Looking for tools Carrying heavy pieces Transferring parts over long distances

Service organization Complicated office layouts Poorly planned meetings Extra signatures needed

Overproduction and double Teams with no directions handling

 The most dangerous kind of waste is the waste we do not recognize." ~ Shigeo Shingo

THANK YOU