slide1 n.
Download
Skip this Video
Loading SlideShow in 5 Seconds..
Lean PowerPoint Presentation
Download Presentation
Lean

Loading in 2 Seconds...

play fullscreen
1 / 20

Lean - PowerPoint PPT Presentation


  • 220 Views
  • Uploaded on

Lean. Manufacturing. Basic Overview. Lean Manufacturing. Is a way of life. It is a never ending process…… Its tools need to tailored to meet XYZ Company’s needs. Not a “one size fits all” method. . Lean Manufacturing Defined.

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' - alaric


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
slide1

Lean

Manufacturing

Basic Overview

slide2

Lean Manufacturing

  • Is a way of life. It is a never ending process……
  • Its tools need to tailored to meet XYZ Company’s needs.
  • Not a “one size fits all” method.
lean manufacturing defined
Lean Manufacturing Defined

“A systematic approach to identifying and eliminating waste (non-value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection”

--The MEP Lean Network

WASTE

WASTE

SUPPLIER

XYZ Company

CUSTOMER

WASTE

WASTE

slide4

Lean Manufacturing Objectives

OUR

CUSTOMER

XYZ Company

“Strealthy”

growth

Satisfaction

ASSEMBLY

PROCESS

Elimination of

mudaor waste

the principles of lean manufacturing
The Principles of Lean Manufacturing
  • Focus on Value - Your customer determines value.
  • Eliminate Waste - Eliminate all forms of waste.
  • Build only what customer Pulls
  • Quality, Quality, Quality

….Jim Womack

what is waste
What is Waste?

“Anything that adds Cost

to the product

without adding Value”

Value = ?

Ask yourself – IS MY CUSTOMER PAYING FOR THIS ?

Yes – Can I do it faster, better, safer ?

No – Why am I doing it ?!

cost profit relationship
Cost – Profit Relationship

COSTS INCREASES

V

V

V

PROFIT DECREASES

the never ending cycle
The Never Ending Cycle…..

Value !!

Low Cost

High Quality

Availability

XYZ Company

OUR

CUSTOMER

how can we make increase profits
How can we make/increase PROFITS ?

Selling Price

Increase our selling price

P

Selling Price

P

XYZ Company’s Cost

P

Decrease our cost

XYZ Company’s Cost

Decrease our cost !!! - HOW ?

7 forms of waste

Value added

Value added

Non-value added

7 Forms of Waste

Value - Add

Value - Add

LEAN = ELIMINATING THE WASTES

slide11

7 Forms of Waste

  • Overproduction – Producing faster than consumption
  • Defects– Variations and complexity
  • Non-value added processing – Lack of standard methods
  • Waiting – Producing slower than consumption
  • Transportation – Disconnected operations
  • Excess motion– Lack of better processes
  • Excess inventory– Long lead times, ……..
bricklaying through late nineteenth century
Bricklaying, through late Nineteenth Century
  • The brick weighs about five pounds (2.3 kg). How much is the worker actually raising and lowering every time he bends over for another brick?

Source: Levinson Productivity Systems, P.C.

http://www.ct-yankee.com/lean/usa.ppt

bricklaying after frank gilbreth
Bricklaying, after Frank Gilbreth
  • The joke about the underachievers and the light bulb isn't so funny any more.
  • Lesson: waste can, by long habit ("living with it," "working around it") become built into a job.

Source: Levinson Productivity Systems, P.C.

http://www.ct-yankee.com/lean/usa.ppt

slide14

INVENTORY – Ship Analogy

GOOD OR BAD ?

Inventory Level

Finished Goods

Raw Material

Long Lead Time

Poor Quality

Poor Training

Poor Housekeeping

Downtime

Poor Layout

No Standards

Scrap

Long Setups

Poor Communication

Poor Scheduling

Supplier Relations

slide15

INVENTORY – Ship Analogy

Cannot reduce inventory instantaneously!

Finished Goods

Raw Material

Inventory Level

Long Lead Time

Poor Quality

Poor Training

Poor Housekeeping

Downtime

Poor Layout

No Standards

Scrap

Long Setups

Poor Communication

Poor Scheduling

Supplier Relations

slide16

INVENTORY – Ship Analogy

Solve problems – Remove rocks before lowering inventory!

Finished Goods

Raw Material

Inventory Level

Poor Housekeeping

Downtime

Poor Layout

No Standards

Scrap

Long Setups

Poor Communication

Poor Scheduling

Supplier Relations

identify waste in your cell
Identify waste in your cell
  • Re-pack
  • Scrap
  • Load/Unload
  • Containment
  • Expedite
  • Counting
  • Sorting
  • Storing
  • Invoices
  • Rework
lean manufacturing tools
Lean Manufacturing Tools
  • Value stream mapping
  • Quality at the source
  • Workplace organization: 5S
  • TPM
  • Visual Management
  • Set-up reduction (SMED)
  • Batch size reduction (one-piece-flow)
  • Cellular manufacturing
  • Standardized work (CYCLE Time)
  • Work balancing (TAKT Time)
  • Production leveling / smoothing / Heijunka
  • Point-of-use systems
  • Kanban
  • Kaizen
lean building blocks
Lean Building Blocks

Continuous Improvement

Pull/Kanban

Cellular/Flow

Quick Changeover

Quality at Source

Plant Layout

Batch Reduction

TPM

5S System

Standardized Work

Visual Systems

POUS

Value

Stream

Mapping

Teams/Employee Involvement

Source: The MEP Lean Network

toyota production system
Toyota Production System

Best Quality - Lowest Cost - Shortest Lead TimeThrough Eliminating Waste

Just in Time“The right partat the right timein the right amount”

Jidoka“Built in Quality”

  • Manual / Automatic Line Stop
  • Labor-Machine Efficiency
  • Error Proofing
  • Visual Control
  • Continuous Flow
  • Pull System
  • Level Production (Heijunka)

Flexible, Capable,Highly Motivated

People

Operational Stability

Standardized Work

Total Productive Maintenance

Robust Products & Processes

Supplier Involvement