Lean manufacturing
This presentation is the property of its rightful owner.
Sponsored Links
1 / 8

Lean Manufacturing PowerPoint PPT Presentation


  • 100 Views
  • Uploaded on
  • Presentation posted in: General

Lean Manufacturing. Superfactory ® Lean Enterprise Series. Contents. Introduction. Background and History. Components and Implementation. 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P)

Download Presentation

Lean Manufacturing

An Image/Link below is provided (as is) to download presentation

Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author.While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server.


- - - - - - - - - - - - - - - - - - - - - - - - - - E N D - - - - - - - - - - - - - - - - - - - - - - - - - -

Presentation Transcript


Lean manufacturing

Lean Manufacturing

Superfactory® Lean Enterprise Series


Contents

Contents

  • Introduction

  • Background and History

  • Components and Implementation

  • 5S & Visual Factory

  • Cellular Manufacturing

  • Jidoka

  • Kaizen

  • Poka Yoke & Mistake Proofing

  • Quick Changeover & SMED

  • Production Preparation Process (3P)

  • Pull Manufacturing & Just In Time

  • Standard Work

  • Theory of Constraints

  • Total Productive Maintenance

  • Training Within Industry (TWI)

  • Value Streams

  • Knowledge Check

© 2007 Superfactory™. All Rights Reserved.


Lean vs traditional processes

Lean vs. Traditional Processes

  • Half the hours of engineering effort

  • Half the product development time

  • Half the investment in machinery, tools and equipment

  • Half the hours of human effort in the factory

  • Half the defects in the finished product

  • Half the factory space for the same output

  • A tenth or less of in-process inventories

  • Smaller lot sizes

  • Increased capacity / throughput

  • Higher inventory turns

  • More available floor space

  • Improved workplace organization

  • Improved quality : reduced scrap / re-work

  • Reduced inventories : raw, WIP, FG

  • Reduced lead times

  • Greater gross margin

  • Improved participation & morale

Source: The Machine that Changed the World, Womack, Jones, and Roos, 1990.

© 2007 Superfactory™. All Rights Reserved.


Background and history

Background and History

  • 1574: King Henry III watches the Venice Arsenal produce finished galley ships every hour using continuous flow processes

  • 1799: Whitney perfects the concept of interchangeable parts

  • 1902: Sakichi Toyoda establishes the jidoka concept

  • 1910: Ford moves into Highland Park, the “birthplace of lean manufacturing,” with continuous flow of parts

  • 1911: Sakichi Toyoda visits the U.S. and see the Model T line for the first time

  • 1938: JIT concept established at Toyota

  • 1940: Consolidated Aircraft builds one B-24 bomber per day, witnessed by Ford’s Charles Sorensen, who later improves production to one B-24 per hour

  • 1949: Taiichi Ohno promoted to shop manager at Toyota, develops “elimination of waste” concept

  • 1951: Ohno refines TPS to include visual control, employee suggestions, TWI, batch size reduction, and kanban

  • 1965: Toyota receives Deming Prize for Quality

  • 1975: First English translations of TPS are drafted

  • 1980-83: First books on TPS by American authors: Kanban and Zero Inventories

  • 1990: Womack and Jones publish The Machine That Changed the World, becoming the definitive text creating the term “lean”, followed by Lean Thinking in 1996

A very detailed historical timeline is available at www.superfactory.com

© 2007 Superfactory™. All Rights Reserved.


Key figures in lean history

Key figures in lean history

  • Henry Ford

    • Founder of the Ford Motor Company and father of modern assembly lines used in mass production.

  • Taiichi Ohno

    • Long-time employee of Toyota, and author of several books about the Toyota Production System.

  • Shigeo Shingo

    • A Japanese industrial engineer who became a leading expert on the Toyota Production System. More than a dozen of his books were translated into English, resulting in him being better known in the West than in Japan.

  • James Womack

    • Author of The Machine That Changed the World and Lean Thinking, which jump-started the lean movement in North America

© 2007 Superfactory™. All Rights Reserved.


Components and implementation

Components and Implementation

  • 5S & Visual Factory

  • Cellular Manufacturing

  • Jidoka

  • Kaizen

  • Poka Yoke & Mistake Proofing

  • Quick Changeover & SMED

  • Production Preparation Process (3P)

  • Pull Manufacturing & Just In Time

  • Standard Work

  • Theory of Constraints

  • Total Productive Maintenance

  • Training Within Industry (TWI)

  • Value Streams

© 2007 Superfactory™. All Rights Reserved.


5s and visual factory

5S and Visual Factory

  • 5S

    • A method of workplace organization

    • Reduces wastes due to clutter, time to find materials and equipment, duplication of equipment, floorspace, inconsistency

  • Components of 5S

    • Sort

    • Straighten

    • Shine

    • Standardize

    • Sustain

  • 5S “+1” or “6S”

    • Some companies add a sixth “S” for Safety

© 2007 Superfactory™. All Rights Reserved.


Training within industry twi

Training Within Industry (TWI)

  • An often forgotton core component of lean

  • TWI provides a systematic approach to sustain changes and continuously improve by

  • Indoctrinating people into an “improvement” frame of mind.

  • Teaching people how to identify opportunities for improving their jobs.

  • Training people how to generate ideas to take advantage of these opportunities.

  • Showing people how to get these ideas into practice right away.

  • Creating ownership for people to maintain standard work.

© 2007 Superfactory™. All Rights Reserved.


  • Login