LEAN MANUFACTURING

Akshay Gajghate
Deepesh
Kamal Nagvani
Prakhar Nagori
Snehil Jain
Subhodeep Saha
Sweta Saroj
Tejashwi Kumar

INTRODUCTION
The lean manufacturing technique is a tried and tested system that carries
many promises for the Indian automobile manufacturer
Most of the Indian automobile manufactures suffer from abnormally high
inventory levels, high cycle times and enormous wastage

Lean is a source for productivity improvements and cost reductions in

manufacturing
Lean enables the companies to response quickly and profitably and
changes in customer demand

The technique of lean can be applied to every situation in a company, by

finding out what the customer want, eliminating, waster from process and
making the value flow continuously according to the customers pull

OBJECTIVES OF LEAN
MANUFACTURING
The five main objectives of a lean manufacturing system are:
1. To produce the highest possible quality product,

2. at the lowest possible cost of manufacturing,

3. within the shortest possible delivery time,
4. with the aim of just not satisfying the customer but delighting the customer,
5. And ensuring a very good after sales service.

UNDERSTANDING WASTE AND ITS

ELIMINATION
Simply if it doesnt add value, it is waste
The central theme of the concepts of lean manufacturing is based on the
systematic identification of waste and its subsequent elimination
In its most basic form, the lean concept eliminates waste through continuous
process improvement
Seven Types of Waste
1
2
Over production Unnecessary
Inventory

3
Defects

4
Inappropriate
Processing

5
Excessive
Transportation

6
waiting

7
Unnecessary
Motion

There are three types of information waste (i) Planning, (ii) Scheduling, and
(iii) Execution waste

PRINCIPLES OF LEAN MANUFACTURING

LMs essences lies in producing with as few people as little inventory and as
little waste as possible
Lean embraces every facet of organization sourcing, manufacturing,
marketing, accounting and strategic planning

Improving the workplace and standardization of workplace is an important

concept in lean manufacturing
For this purpose 5S concept is used :iv.
Standardization:
- Itabout
involves
creating
a consistent
approach
carrying
out
tasks
i.iii.
Sort:
stage
whichorderly
towards
organizing
the
work
area,
only
the
tools
and
Shine:
-isIta
keeping
everything
clean.
This
maintains
aleaving
safer
work
area
ii.
Set
in- Itorder:
- Itabout
tells
arrangement
of needed
items
so
they
are
easy
toand
use
v.
Sustain:
-tells
Itfirst
aims
at
maintaining
discipline
and commitment
offor
all
other
stages.
Itand
lead
to and
procedures
materials
necessary
to perform
activities
problem
areefficiency
quickly
accessible
anyone
toidentified
find
increaseareas
infor
work
anddaily
higher
job satisfaction

BASIC PILLARS IN LEAN

MANUFACTURING

I. JUST IN TIME CONCEPT:The goal JIT is achieved by

using techniques like
standardizations of
processes, TPM and
Kanban. The
manufacturing unit can
achieve following goals.
Reduce set time.
Guaranty that material
will be there without
excess handling.
Guaranty of machine
availability and reliability.

II. SUPPLY CHAIN

INTEGRATION:- A
long process
involving several
interfaces, and so
manufacturers
need to take steps
towards strategic
sourcing and
organizing the
supply base

III. CELLULAR
TECHNOLOGY:Manufacturing cell is
designed to process
parts of the product
in separate fixed
areas, thus
eliminating non
value-added
activities. Ultimately,
the layout creates a
single-piece flow

IV. KAIZEN:- Continuous

Improvement, without
spending much
money using
common sense. It
doesnt cost money but
it changes the way
people do the job. It is
about making the most
about 5-M of the
organization i.e
1. Manpower 2.Material
3.Mathod 4.Machine
5.Measurement

IMLPEMENTATION OF LEAN
MANUFACTURING SYSTEM
The process of going lean starts with attitude level, not at the shop floor
level
The arrangement has to bring about the following TECHNICAL CHANGES:
iii)
Make
fixture,
holders,
tolling,
adaptable
all parts
with
minimum
i)
firstthe
step
towards
the lean
production
is
toto
make
such
process
of
consistentsetup
and change
ii)The
Standardize
the process
sequence
forfor
all zero
this
similar
looking
/zero
typeor
/production
category
parts,
which
iv)
Simple
and
autonomous
machines
v)
Preventive
maintenance
of
machine
break
downs
during
time
predictable
production
may have minor
difference in size. This will help in shop layout for continuous material flow.

The management should also bring about the following ADDITIONAL

CHANGES:
vi)
Use
statistical
tolls
and
imbibe
statistical
thinking
cause
effect
and
iii)
Catching
defect
upstream
vii)
i)
TPMof
aims
at
skillzero
and
accidents,
will
into
military
breakdowns
drillfuturestage
and particularly
zero defects.
TPM and
again
is enhanced
by
ii) Converting
v)
Pre-emptying
Responsibility
to
future
be
passed
problems
onzero
at
downwards
planning
iv)
Checking
to
be
done
to
ensure
safe
production
frequency
distribution
the calculation
of Overall Equipment Effectiveness. (OEE)
OEE = Availability * Performance Rate * Quality

ADVANTAGES OF LEAN
MANUFACTURING
Since Lean involves the JIT inventory levels (raw material, WIP, finished goods) can be brought
down to nearly nil, thus reducing cost
Lean uses simple multitask machinery where by product of different design can be produced on the
same machine.
Transition between various designs takes only a few minutes. This enables increase in flexibility and
better response to customer requirements.
It also reduces customer lead time, cost of production and wastage.
Lean helps to unleash the power of the work force, ultimately taking the organization to, a competitive
position.

TRADITIONAL MANUFACTURING VS
LEAN MANUFACTURING
Sr. no.

Major Aspects

Traditional manufacturing

Lean Manufacturing

1.

waste

Maximum

Minimum

2.

Approach to Efficiency

Individual process

Overall System

3.

Philosophy

Output-centered

Market Centered

4.

Scheduling

Push

Pull

5.

Production

Stock

JIT

6.

Lead time

Long

Short

7.

Batch Size

Long Batch & Queue

Small Continuous Flow

8.

Inspection

Sampling

100% at source

9.

Shop floor Layout

Activity based

Cellular Manufacturing

10.

Empowerment

Low

High

11.

Inventory turns

Low

High

12.

Flexibility

Low

High

OBATACLES ON LEAN PATH

Top management lacks strategic understanding of lean.
Lack of specific skills or knowledge regarding lean enterprise.
Culture, ego, organizational inertia.
Management reluctance to empower employees.
Fear of change of loss of organizational power.
Internal system causing hurdles.
Old engineering concepts.
Inflexible accounting methods

SUSTAINABILITY THROUGH LEAN

MANUFACTURING
Seven examples of how these lean innovations can yield sustainability results
for manufacturers:
i)

Fewer product defects

ii) Less overproduction

iii) Minimizing wasted movement
iv) Reducing transportation
v) Less excess inventory

vi) Reduced waiting

vii) Less over-processing

THANK YOU