LEAN PRODUCTION

D.VASANTH KUMAR, 09MF71

PSG COLLEGE OF TECHNOLOGY, COIMBATORE
What is lean production?

 Lean Manufacturing

 Business philosophy that was originally developed at the

Toyota motor company
Objective

 To eliminate all forms of waste in the production process

SEVEN FORMS OF WASTE
 Overproduction
 Waiting for machines or operators
 Transportation waste
 Process waste resulting from inefficient, poorly designed
processes
 Excessive inventory
 Wasted motions
 Waste of rework through producing defects
LEAN HISTORY
 1903 ,Henry Ford - Model A, need for closer tolerances of
thousands of disparate parts, a must for success in mass
production
 Interchangeability – mass production
 Specialization Of Labor – Productivity increased
dramatically from shorter learning cycles and subsequent
perfection of the specialized task
Simple design
 1914- Highland Park Model T plant, Conveyor
 Almost a 100% increase in productivity was achieved
with this one change.
 Maintaining close tolerances of thousands of disparate
parts from many different suppliers led Ford to bring all
suppliers in house for complete vertical integration
1949
 Taiichi Ohno- Engineer of Toyota Motor Company visited
Ford’s River Rouge plant at Detroit
 Mass production
 Expensive press and die machines
 Heavy capital investment
 Die changes at the river rouge plant required at least 1 day
 Ohno realized this system would not work for Toyota
 production was only a few thousand vehicles per year,
compared to millions produced in Detroit
 Extensive experimentation
 Decrease the time and labor required to change dies
 Toyota began scheduling changes every 2 to 3 h

 Short production runs became the norm for Toyota,

resulting in fewer inventories of finished goods on hand.
And because the production cycle to produce one
completed vehicle was shortened
Quality issues
 Earlier detection of defective parts translated to less
rework, which drove down production costs while
increasing the quality of the final product
 Toyota has refined their Lean Production methods to
become one of the highest quality producers of value-
priced vehicles