Professional Documents
Culture Documents
Lean Manufacturing
Lean manufacturing is a systematic approach to identifying and eliminating wastes through continuous improvement by conveying
the product at the pull of the customer in pursuit of production.
Lean Manufacturing is a systematic approach for achieving the shortest possible cycle time by eliminating the process waste
through continuous improvement. Thus making the operation very efficient and only consisting of value adding steps from start to
finish. In simple words lean is manufacturing without waste.
Below are the few steps which are required to implement lean manufacturing
Analyzing the wastes and finding the root causes for these wastes.
Pursuing perfection
Reduce Time
Awareness of Waste
Cost Reduction versus Cost Plus
Lean Manufacturing improves productivity through the principle of Cost Reduction.
With the principle of cost reduction, the sales price of a product is determined by actual market
conditions. A profit cannot be secured, thus, without first reducing cost regardless of increases
or decreases in the production quantity. This type of cost philosophy requires an overall
company effort. Cost reduction is:
Profit = Sales price Cost
In contrast to cost reduction, there is the cost-plus principle, in which product price is
determined by combining all the costs -- such as those of raw materials, labor and other
expenses needed for production -- with whatever company policy decides is needed as profit.
Cost policy:
Sales price = Cost + Profit
The two formulas above are the same mathematically, but there is a great difference in the
emphasis each one places on the variables. In other words, cost-plus considers that the cost is
fixed. While cost reduction considers, that the cost can be effectively changed by
manufacturing methods.
Overproduction
It is unnecessary to produce more than the customer demands, or producing it too early before it is needed. This increases the risk
of obsolescence and the risk of producing the wrong thing. It tends to lead to excessive lead and storage times. In addition, it leads
to excessive work-in-process stocks which result in the physical dislocation of operations with consequent poorer communication
Defects
In addition to physical defects which directly add to the costs of goods sold, this may include errors in paperwork, late delivery,
production according to incorrect specifications, use of too much raw materials or generation of unnecessary scrap. When defect
occurs, rework may be required; otherwise the product will be scrapped. Generation of defects will not only waste material and labor
resources, but it will also create material shortages, hinder meeting schedules, create idle time at subsequent workstations and
extend the manufacturing lead time.
Inventory
It means having unnecessarily high levels of raw materials, works-in-process and finished products. Extra inventory leads to higher
inventory financing costs, higher storage costs and higher defect rates. It tends to increase lead time, prevents rapid identification of
problems and increase space requirements. In order to conduct effective purchasing, it is especially necessary to eliminate
inventory due to incorrect lead times.
Transportation
It includes any movement of materials that does not add any value to the product, such as moving materials between workstations.
Transportation between processing stages results in prolonging production cycle times, the inefficient use of labor and space. Any
movement in the
firms could be viewed as waste. Double handling and excessive movements are likely to cause damage and deterioration with the
distance of communication between
processes.
Waiting
It is idle time for workers or machines due to bottlenecks or inefficient production flow on the factory floor. It includes small delays
between processing of units.When time is being used ineffectively, then the waste of waiting occurs. This waste occurs whenever
goods are not moving or being worked on. This waste affects both goods and workers, each spending time waiting. Waiting time for
workers may be used for training or maintenance activities and should not result in overproduction
Motion
It includes any unnecessary physical motions or walking by workers which divert them from actual processing work. This might
include walking around the factory floor to look for a tool, or even unnecessary or difficult physical movements, due to poorly
designed ergonomics, which slow down the workers. It involves poor ergonomics of production, where operators have to stretch,
bend and pick up when such actions could be avoided.
Over-processing
It is unintentionally doing more processing work than the customer requires in terms of product quality or features such as polishing
or applying finishing in some areas of product that will not be seen by the customer . Over-processing occurs in situations where
overly complex
solutions are found to simple procedures. The over-complexity discourages ownership and encourages employees to overproduce
to recover the large investment in the complex machines.
The Eighth Waste Skills
Sometimes in focusing on the elimination of the seven wastes, companies forget about the aspect of Lean that is inherent in the
philosophy as it was originally developed in Japan respect for people. In other words, the recognition that a companys most
important assets are its employees. To that end, Lean practitioners sometimes add an eighth waste to the list skills. This waste
occurs when company does not fully leverage the gifts and talents of its associates. In fact, employees may even decide to leave a
company for the simple reason that they do not feel as though they are being listened to or valued, and, as such, they feel like a
number in a sea of numbers.
Value
Specify value from the standpoint of the end customer by product family.
2.
Identify all the steps in the value stream for each product family, eliminating whenever possible those steps that do not create value.
3.
Flow
Make the value-creating steps occur in tight sequence so the product will flow smoothly toward the customer.
4.
Pull
As flow is introduced, let customers pull value from the next upstream activity.
5.
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.
Value stream mapping is the identification of all the specific activities (material and information
flow) as well as the resulting lead times occurring along the value stream for a particular product or
product family, usually represented pictorially in a value stream map.
Takt Time
Takt time is the rate at which product must be turned out to satisfy market demand. It is determined
by dividing the available production time by the rate of customer demand. It is a calculated number,
not a reflection of your capability. It sets the pace of production to match the rate of customer
demand.
EPEI
A measure of how frequently a process can produce all the items assigned to it. For example, if a machine is able to change over
and produce the required quantity of all the high-running part types dedicated to it within three days, then the production batch size
for each individual part type is about three days worth of parts. Thus this machine is making every part every three days.
Leveling (Heijunka)
Leveling is the sequencing of orders in a repetitive pattern, and the smoothing of day-to-day
variations in total orders to correspond to longer-term demand.
Pull Systems
A pull system is a system of production and delivery instructions in which nothing is produced by
the upstream supplier until the downstream customer signals a need. Pull can operate with single
units or small batches. It enables production without preset schedules.
checklists, worksheets, diagrams, area maps, etc., and may pertain to equipment use, operations,
processes, metrics, storage, safety, quality, movement in an area, or general use of the environment.
Setup Reduction (Single Minute Exchange of Dies or SMED)
SMED is a series of operator techniques pioneered by Shigeo Shingo that result in changeovers of
production machinery in less than ten minutes. The long-term objective is always zero setup, in
which changeovers are instantaneous and do not interfere in any way with one-piece flow.
Poka-yoke (Mistake Proofing)
Japanese term used by Shigeo Shingo to mean "innocent mistake-proofing," it is an improvement
technology that uses a device or procedure to prevent defects or equipment malfunction during
order-taking or manufacture. Mistake proofing devices are important to the production line in
several ways:
(1) enforce correct operations by eliminating choices that lead to incorrect actions,
(2) signal or stop a process if an error is made or a defect created
(3) prevent machine and product damage.
5S
Five S (5S) an improvement process, originally summarized by five Japanese words beginning
with S, to create a workplace that will meet the criteria of visual control and lean production. Seiri
(sort) means to separate needed tools, parts, and instructions from the unneeded and to remove
the latter. Seiton (set in order) means to neatly arrange and identify parts and tools for ease of use.
Seiso (shine) means to clean and inspect. Seiketsu (standardize) means to require as the norm that
everyone sort, set in order, and shine at frequent (daily) intervals to keep the workplace in perfect
condition, and also to make use of visual control systems. Shitsuke (sustain) means to maintain the
five S gains by training and encouraging workers to form the habit of always following the first
four Ss.
SEVEN QC TOOLS:
Histogram
Pareto chart
Control chart
Scatter diagram
JIT (JUST IN TIME):
Just in time (JIT) is a production strategy that strives to improve a business return on investment by reducing in-process inventory
and associated carrying costs. To meet JIT objectives, the process relies on signals or Kanban between different points in the
process, which tell production when to make the next part. Kanban are usually 'tickets' but can be simple visual signals, such as the
presence or absence of a part on a shelf. Implemented correctly, JIT focuses on continuous improvement and can improve a
manufacturing organization's return on investment, quality, and efficiency. To achieve continuous improvement key areas of focus
could be flow, employee involvement and quality.
KANBAN TOOLING:
Kanban is one of most popular tools in lean manufacturing. This is a simple concept, but very effective. Kanban mainly focus on the
reduction of overproduction. There are mainly two types of kanbans. They are
Withdrawal kanban
Production kanban
Quality performance, fewer defects and rework (in house and at customer).
Faster Development.
HIGHER PROFITS!
INCREASED BUSINESS