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 Toyota auto manufacturing Value chain

Changed the World

Waste Categories

Overproducing
Inventory Waiting Extra Processing Correction Excess Motion Transportation Underutilized People

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

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

INVENTORY

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

WAITING

TRANSPORTATION
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:

Man Activities of operator machine - Manner in which the equipment is used Material - the changes the material undergoes in location or condition
Process

circles for operations

arrows for transports squares for inspections triangles for storage letter D for delays.
Before Layout Revision
Sl. No . 1 2 3 4 5 6 7 8 9 10 11 12 Operation M achine

Storage Coining Storage + Relief Plug Assy. Ball Pressing Storage Leak Check Storage Poppet assembly Bearing Pressing Storage Thrust washer Assy. Storage
Total

From In trolley Press Trolley Press On the Machine Air Gauge Table Table Press Table Poka-Yoke -6 6 0 1 4

After Layout Revision

Sl. No. Operation Machine

Process

1 2 3 4 5 6

Storage Coining Bearing Pressing Ball Pressing Leak Check& Poppet Assy. Thrust washer Assy.

In trolley Press Press Press Table PokaYoke

1 5 0 0 0

Total

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

BEFORE
Before Layout Revision
Sl. No . 1 2 3 4 5 6 7 8 9 10 11 12 Operation M achine

Process

Storage Coining Storage + Relief Plug Assy. Ball Pressing Storage Leak Check Storage Poppet assembly Bearing Pressing Storage Thrust washer Assy. Storage
Total

From In trolley Press Trolley Press On the M achine Air Gauge Table Table Press Table Poka-Yoke -6 6 0 1 4

Storage Process Inspection Waiting -

6 6 1 4

storage operation transportation

inspection waiting

AFTER
After Layout Revision
Sl. No. Operation Machine

Process

1 2 3 4 5 6

Storage Coining Bearing Pressing Ball Pressing Leak Check& Poppet Assy. Thrust washer Assy.

In trolley Press Press Press Table PokaYoke

1 5 0 0 0

Total

Storage - 1 Process - 5