Date post: | 03-Aug-2015 |
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Engineering |
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PRESENTATION ON LEAN
MANUFACTURING
By Ashish R. Sontakke
M.Tech.Cad-Cam Roll No.-16
VNIT
What is LEAN MANUFACTURING??
“The production of goods using less of everything by reducing ‘waste’ and increasing value
added activity”
ORIGIN
Lean Manufacturing is sometimes called the Toyota Production System (TPS) because Toyota Motor Company’s Eiji Toyoda and Taiichui Ohno are given credit for its approach and innovations
“Key” Lean Manufacturing Techniques
1. Elimination of waste2. 5s3. JIT/Pull production system4. Cellular Manufacturing5. KANBAN
What is Waste?
• Waste is anything that happens to a product that does not add value from the customer’s perspective
• Products being stored, inspected or delayed, products waiting in queues, and defective products do not add value
The 8 wastes
Introduction to ‘TIM WOODS’ T – Transport
I – InventoryM – MovementW – WaitingO – Over-processingO – Over-productionD - DefectsS - Skill
5s
1.Seiri -Sorting2.Seiton-Stabilizing or Straightening Out3.Seiso-Sweeping or Shining4.Seiketsu-Standardizing5.Shitsuke-Sustaining the Practice
5S Examples
Before After
JIT/Pull system
• JIT literally means Just In Time.• It aims to produce only what is needed, when
it is needed. • Production is pulled by the downstream
workstation so that each workstation should only produce what is requested by the next workstation.
• One-piece flow is key implementation which means that parts are moved through operations from step-to-step with no WIP in between either one piece at a time or a small batch at a time.
Gravity Conveyor for one piece flow between two machines
Cellular manufacturing
1.In Functional Manufacturing similar machines are placed close together (e.g. lathes, millers, drills etc.).
2.In Cellular Manufacturing systems machines are grouped together according to the families of parts produced.
3.The major advantage is that material flow is significantly improved, which reduces the distance travelled by materials.
Cellular manufacturing
Example of Cell
KANBAN
A system of continuous supply of components and parts such that workers have what they need, where they need, when they need it
KANBAN is the process through JIT is achieved
Assembly line (KANBAN)
Key Implications of lean manufacturing
Traditional LeanOrientation Supply driven Customer driven
Planning Orders are pushed though factory based on production plan/forecast
Orders are pulled through factory based on customer/downstream demand
Batch size Large small
Quality inspection
Checking of samples by QC inspectors
In-line inspection by workers
Inventory Buffer of work-in-progress
Little or no work-in-progress
Advantages
• Increased overall productivity• Reduced amount of floor space required• Reduced manufacturing lead time• Improved flexibility to react to changes• Improved quality• Less inventory• Increases working standards• Increases worker talents
Disadvantages
• Success of lean requires the full commitment and involvement of all employees.
• Long term commitment required (i.e. workers should give full support to apply lean)
THANK YOU