2What is Lean Manufacturing System? Lean Manufacturing System is systematic approach to identifying and eliminating waste (non-value added activities) through continuous improvement by flowing the product only when the customer needs it (called “pull”) in pursuit of perfection.
3Lean Manufacturing System LMS is a production management system which aims to provide the customers:What they want.How they want it.Where they want itAt a competitive price.In the quantities and varieties they wantAlways of expected quality
4Why do we need LMS?To meet the challenge of competing in globalised markets.Continued Market place focus on quality, cost and delivery (QCD)Pressure of out sourcing by OEM?Ever increasing customer expectations.The need to compete effectively in the global economyPressure from customers for price reductionsContinued marketplace focus on quality cost and on-time delivery.
5Analysis of Traditional System of Manufacturing Starts in factoryProduction plan based on demand forecastMaterial procurement to meet production planMaterial receipt and inspectionStorage of materials and components till required for processingActual production in various process stations with stress on maximizing productionStorage of components required for assemblyAssembly , final inspection and packagingStorage of finished goods in company godowns and zonal depotsOn the shelf in retail outlets.Ends with the customerSince the product is pushed from factory to the customer, this system is also known as ‘PUSH’ system.
6Weakness of Traditional System Risk related to forecasts.Long overall business process cycle.Good comfort level at various stages leading to slack in the system.It hides the problems, waste and obstacles in the business flow.Encourages departmental focus as their efficiency is judged on the basis of output. (departmental enterprise)Pushes up costs and affects competitiveness..
7Core of LMS is waste reduction leading to: Improved qualityHigher through putBetter efficiencyHigher profitability.
87 Types of waste1. Waste due to non standardization and variation in production processes.2. Waste due to inadequate capacity utilization3. Waste due to waiting time of men, machines and material.4. Waste due to unnecessary movement of material5. Waste due to pre-process and in-process inventory.6. Waste in the process itself (due to excessive cycle time and consumption of direct material, indirect material & energy).7. Waste due to producing defective goods and unnecessary
9What is Lean Manufacturing System (LMS) Basic Objective of LMS is to do more and more with less and less human effort, less equipment, less time and less space. At the same time coming closer and closer to providing customers what exactly they want.LMS concentrates on business process time line.Order cashLMS aims to reduce the time line by reversing the sequence of activities and eliminating non value added operations.Time line
10Flow in Lean Manufacturing System Starts with customerOrder acquisition by marketingProduction planningJust in time receipt of materialPull system of production down the entire process chain by kanban, a control tool starting from sales dispatch section.Since the customer pulls the product, it is also called pull system of manufacture.Ends with primary producers
12Key Principles1. Minimize material handling. Preference should be given to low or no- cost solutions such as gravity-feed slides. Handle product once only.2. Minimize distances. Avoid walking, carrying, etc. by creating cells, combining operations within a work centre, better planning, and so on.
13Key Principles...3. Minimize strain. Work centres should be ergonomically designed to avoid back and other muscle strains.4. Minimize clutter. Everything should have a home, from parts and tools at a workstation, to equipment and product within designated floor spaces.5. Minimize storage. If you have the space, it will surely get filled. Thus, continuously minimize your storage space for raw material, WIP, finished goods and spare parts throughout the supply chain.
14Key Principles...6. Maximize utilization. Make optimal use of people, space, and equipment to improve the return on investment.7. Maximize flexibility. The key to lean is creating a layout that can adapt quickly to changes in product, equipment, personnel, or material.8. Maximize smooth flow. Continuously determine and eliminate the bottlenecks, then re-balance the line.
15Key Principles...9. Maximize visibility. To quickly spot problems, maintain a clear line of vision to anywhere, from anywhere.10. Maximize communication. Lean requires constant training on tools available to meet goals and objectives, and feedback on how well things are going.
16Tools of LMS JIT Total productive maintenance 5 S Process optimization Visual ControlsStreamlined layoutStandardized work.Batch size reductionQuality at the sourcePoint of use storageQuick changeoverPull and Kanban