lean manufacturing
Download
Skip this Video
Download Presentation
Lean Manufacturing

Loading in 2 Seconds...

play fullscreen
1 / 8

Lean Manufacturing - PowerPoint PPT Presentation


  • 140 Views
  • Uploaded on

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)

loader
I am the owner, or an agent authorized to act on behalf of the owner, of the copyrighted work described.
capcha
Download Presentation

PowerPoint Slideshow about 'Lean Manufacturing' - lucinda


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.

ad