By Rajashree. R Kiruba.

 The

concept of Lean Manufacturing was

was the first company to introduce

developed by Henry Ford in 1920s.

Toyota

lean manufacturing concept in its production system.

Lean

manufacturing focuses on reducing

waste.

 The

core idea is to maximize customer value

while minimizing waste.

Simply, lean means creating more value for customers with fewer resources.

lean organization understands customer

value and focuses its key processes to

continuously increase it.

To

provide perfect value to the customer

through a perfect value creation process that

has zero waste.

 To
To To To

create continuous flow .

use pull-systems to manage the workflow

reduce batch sizes and inventories

eliminate waste use of automation

Selective To

instill a Continuous Improvement competence

Traditional Manufacturing Scheduling Forecast - push

Lean Manufacturing Customer Order - pull

Production
Lead Time Batch Size Inspection Layout Empowerment

Stock
Long Large - Batch & Queue Sampling - by inspectors Functional Low

Customer Order
Short Small - Continuous Flow 100% - at source by workers Product Flow High

Inventory Turns
Flexibility COGS

Low - <7 turns

Low High and Rising

High - 10+
High Lower and Decreasing

The following steps should be implemented to

create the ideal lean manufacturing system
Design

a simple manufacturing system that there is always room for

Recognize

improvement
Continuously

improve the lean manufacturing

system design

 Save

money, and reduce costs

valuable resources

Conserve Less

downtime means more productivity waste, and improve efficiency

Eliminate Stop

loosing customers due to quality issues management

Growth Peace

of mind

 Increased
Shorter More

focus on the customer value.

lead times.

efficient resource utilizations.

product quality and less defects.

Higher Work

smarter not harder.

 Lean

techniques are applicable not only in

manufacturing, but also in service-oriented industry and service environment.

Lean

principles have been successfully applied

to call center services to improve live agent call handling.

 Lean

principles have also found application in

software application development and maintenance and other areas of information technology(IT).
Lean

methods were applicable to the public

sector, but that most results had been achieved using a much more restricted range of techniques than Lean provides.

 Supply
High Lack

Problems

Cost of Implementation

of Acceptance by Employees
Dissatisfaction Problems

Customer