LEAN By : SK Muralee Tharan
What is Lean Manufacturing? Introduction to Lean Manufacturing Concept
What is Lean Manufacturing? Lean is a concept based on fundamental principles Lean Lean Principle:Product flows through the manufacturing system
Eliminationof Waste ImprovedFlow = ImprovedFlow DecreasedCost = DecreasedCost = What is Lean Manufacturing? There is a direct link between flow and cost New BusinessSustainable Profits
Evolution Of MANUFACTURING Craft Mass Lean 1857 1900 1925 1950 1975 2000
LEAN OBJECTIVES Inbound Outbound LEAN LAYOUT
Define all activities required to design, order, and provide a specific product, from concept launch, from order to delivery, from raw material into the hands of the customer. THIS INCLUDES : MAPPING VALUE STREAM
Value Adding Any operation or activity that changes, converts , or transforms material into the product that is sold to the customer.
NON-Value Adding Any operation that takes time and resources but does not add value to the product sold to the customer.
WASTE VS Value added PRINCIPLES The major problem within industries today is Waste. One way of identifying waste is to check whether your operation (or activity) add any value to the product or service. Waste is defined by Mr.Fujio Cho (ToyotoCompany,Japan) as “Anything other than the minimum amount of equipment,materials,parts,space, add worker’s time,which are absolutely essential to add value to the product.
Supply chain management- framework Material Flow Information Flow
Flow System Pull System Quick Changeover Mistake Proofing Line Balancing Lean tools
Flow - Proximity Geographically concentrate equipment to perform operations into a “Cell” or “Line.”
FloW-sequence • Design the process and cell so that products are made in the same sequence of operations. • Simplifies cell operation • Minimizes WIP
kanban • Kanban Calculation • -Kanban Order Quantity • The Kanban lot size divided by the kanban container quantity.
Pull system SUPERMARKET
PUSH High Inventory Daily Product (Eggs , Milk, Butter) that you need in a week. Retailer Delivery House Days not sure when ( Mon or Friday). If you go vacation, all product spoilt. Refrigerator Full - 2nd refrigerator & garage
The “supermarket” • A group of products or materials which is stored to respond to instantaneous demand. • Supermarket stock levels are determined through an understanding of typical demand patterns, service policy, and the time it takes to replenish stock. • Also known as Strategic Inventory. “supermarket” Kanban • A strategic inventory approach, which creates a buffer of planned inventory after an operation to mitigate lead-time and potential capacity constraints. • A variation of a min/max approach, this approach would typically include a Kanban signaling device back to the prior operation.
Classification of setup operations • Classify setup operations into waste, internal setups (IED), and • external setups (OED). • - Waste – operation which do not add values to the setup. • - Internal Setups – Operation that can only be performed while • the machine is shut down. • - External Setups – Operation that can be performed without • shutting down the machine. • * Eliminate the waste Internal set ups • Convert as many internal setups as possible to external setups. • - Use standard insert module. • Improve internal setups (include adjustment). • - Use specifically designed cart to organize tools. • - Use quick-release fasteners instead of bolts and nuts.
Speed and flexibility enables ‘pull’ Satisfy demand quickly, replenish quickly Shorter set-up time Smaller batches Shorter replenishment time Lower strategic inventory = = = Shorter lead time , lower inventory, high on-time delivery SUM ….and It’s ‘Lean’
A process improvement Technology that prevents the production of faulty products and avoids the costs related to the disposition and tracking of defects. Mistake proofing (POKA-YOKE) Why Mistake- proofing To establish smooth flow production To enable pull system to work. Improve quality Reduce cycle time. Reduce cost of manufacturing.
The four elements of zqc 1 2 3 4
Types of mistake proofing devices • Guide / reference / interference rod or pin • Template • Limit switch /microswitch • Counter • Odd-part-out method • Sequence restriction • Standardize and solve • Critical condition indicator • Detect delivery chute • Stopper / gate • Sensor • Mistake proof your mistake proofing device : • Eliminate the condition • Redesign for symmetry • Redesign for asymmetry
Line balancing The allocation of resources (people and machinery) to accomplish a series of tasks which minimizes the amount of idle time per resources for a given production volume and time period.