LEAN MANUFACTURING

Presented By:
Gaurav Kumar Manish Gupta Pavan Ghargi

Lean Manufacturing Is:

It is focusing on the ELIMINATION of WASTE (non-value-added activities) through CONTINUOUS IMPROVEMENT!

Lean Manufacturing

3 Pronged Approach

What makes a manufacturing system lean? the 3 Ms of lean

muda waste mura - inconsistency muri - unreasonableness

Value stream mapping

Follow a product or service from beginning to end Draw a visual representation of every process in the material & information flow

Value Stream Mapping

Helps us see where value is created, and where waste exists:

A visual approach, by product family

Shows flow of both material & information Helps us see which specific Lean tools can be used to improve flow and eliminate waste Two maps will be made: Present State (how it is) & Future State (how it should be)

Value Added vs NonValue Added

Value added: Transforms raw material and information into products or services to be marketed Non-value added (waste): Consumes resources but does not contribute directly to the product or service to be marketed

7 Deadly Wastes

What is 5S?
Represents 5 disciplines for maintaining a visual workplace 1)Sort 2)Set in Order (Stabilize) 3)Shine 4)Standardize 5)Sustain

Title
Lorem ipsum dolor sit amet, consectetuer adipiscing elit. Vivamus et magna. Fusce sed sem sed magna suscipit egestas. Lorem ipsum dolor sit amet, consectetuer adipiscing elit. Vivamus et magna. Fusce sed sem sed magna suscipit egestas.

Elements of a 5S Program
SortPerform Sort Through and Sort Out, - red tag
all unneeded items and move them out to an established quarantine area for disposition within a predetermined time. When in doubt, move it out! items and label them. A place for everything & everything in its place.

Set in OrderIdentify the best location for remaining Sweep (Systematic Cleaning)Clean everything,

inside and out. Use visual sweeps to ensure everything is where it should be and that junk is not accumulating. controlling the first 3 Ss. Use visual controls.

StandardizeCreate the rules for maintaining and

Who wants what

Cash !!

Value !!
Customer

Low Cost High Quality Availability

Your Company

Profit Repeat Business Growth

Potential Benefits of Lean

90% reduction of production times 50% increase in productivity 80% quality improvement 75% improvement in space utilization 85% reduction of "work in progress" (stuff waiting to be finished) And reduction of material waste

COST SAVINGS

Before 5S

After 5S

After 5S

After 5S

Comparison of Traditional vs. Lean

Traditional
Complex Forecast Driven Excessive
Inventory

Lean
Simple and
Visual

Speed Up ValueAdded Work Production

Demand Driven Inventory as

Needed

Large Batch Long Lead Time

Reduce NonValue-Added

Small Lot Size Minimal Lead

THANK YOU