1. Lean Manufacturing Series
Lean Overview
Lean Manufacturing Series

2. 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

3. Introduction What is Lean? Thinking Lean
Lean focuses on eliminating waste in processes (i.e. the waste of work in progress and finished good inventories)
Lean is not about eliminating people
Lean is about expanding capacity by reducing costs and shortening cycle times
Lean is about understanding what is important to the customer
Thinking Lean
Specify value from the perspective of the ultimate customer
Identify the value stream to expose waste
Create flow to reduce batch size and work-in-process
Make only what the customer has ordered
Seek perfection by continuously improving quality and eliminating waste

4. Types of Waste Overproduction Excess inventory Defects
Non-value added processing
Waiting
Underutilized people
Excess motion
Transportation

5. 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
Source: The Machine that Changed the World, Womack, Jones, and Roos, 1990.

6. Background and History (cont.)
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
: 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