Lean Manufacturing

Concepts and Tools and

Quality Management

By Hristina Koycheva
What is Lean?
Lean is an Operational Excellence
Strategy that enable you to change
for the better- in fact the Japanese often use
Kaizen which use by lean practitioners to describe
incremental improvements ;
What is Lean?
Persistent process in elimination of
waste MUDA describes any activity thats
done, but add no real value to the product or service.
What is Lean?
Respect for
people

High Quality and

Stable Processes
Where?
At all level there is a strong desire to
be better;
A culture of lean is visibly prioritised
and practice from the top to the
bottom of the workforce;
The key is understanding the
customer and delivering his
requirements;
How?
Improves business performance using simple
practical tools and techniques to enhance
quality, cost, delivery and people contribution;
Exposes the wastes in the system;
People need to change their long standing work
practices and ideas;
Senior management need to drive lean
principles forward with total commitment to its
success;
Not a bolt on technique, more a way of life
leading to a total change in culture.
Short History
1913: Henry Ford
(Start of mass
manufacturing with
the
moving line)

1938 JIT Born

Short History
1950: Eiji Toyoda brings the ideas of
continuous moving
line in Japan
Short History
1960: Toyota
production System,
main principles of
lean manufacturing

1991: Lean
Management
Main Principals
Identify the customer
Map the flow
Make a product or service flow
Create polls based on customer
demands
Continually find ways to improve
Lean Tools
Assessment and
planning-
fundamentals and
understanding where we
are today and creating and
design for tomorrow.

Plan, Do, Check,

Act
Lean Tools
5 S

Visual control

Standardize
work

Total productive
maintenance
Select the key
Select the
key
Reduce cost of
production
Map Process

Increase customer
Establish
Customer
Eliminate
Waste satisfaction
Poll

Make Process
Improve quality
Flow
What Is Waste?
Waste of overproduction (largest
waste)
Waste of time on hand (waiting)
Waste of transportation
Waste of processing itself
Waste of stock at hand
Waste of movement
Waste of making defective products
Lean Thinking
Key Principals of Lean Thinking
Value - what customers are willing to pay for;

Value Stream the steps are delivered value;

Flow organizing Value Stream to be continuous;

Polls responding to downstream customer demand;

Perfection relentless continuous improvement
(culture);

Lean Thinking, Womack and Jones,1996

Conclusion
Lean is:

A systematic approach to identifying and

eliminating waste (non-value added
activities) through continuous improvement
by flowing the product at the pull of the
customer in pursuit of perfection.
Production System
Two pillars:

Jidoka

Just-in-time
What is Jidoka?
Jidoka means
autonomous. The
responsibility of
each associate to
deliver Quality to
the customers.
- Intense Motivation
Training;
- Explained Information;
Just-in-time
Aims of zero
inventory;

Parts are not kept

in warehouse;

Parts arrive when

needed;
Quality system
Quality means
compliance with
specifications- no
less, no more;
No need for
inspections!
Quality Assurance
When we focused
on this we will
consistently deliver
what the customer
expects;

Trust raises
everyones
commitment
Thank you!