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Manufacturing
Lean Manufacturing
Definition
Lean has been defined in many different ways.
Intro-To-Lean
Lean manufacturing is a
philosophy
In 1990 James Womack, Daniel T. Jones, and
Daniel Roos wrote a book called The
Intro-To-Lean
Muda (Waste)
Taiichi Ohno (1912-1990), the Toyota executive who was the most
ferocious foe of waste human history has produced, identified the
first seven types of muda in manufacturing system:
Storage
Transportation
Waiting
Motion
Process
Defects
Over-production
Muda is everywhere.
Intro-To-Lean
Lean Overview
Intro-To-Lean
Intro-To-Lean
Push or Pull?
A push system
Intro-To-Lean
Push or Pull?
A pull system
Intro-To-Lean
Kanban Operation
Kanban Stage
1
Kanban Stage
i
RM
FG
Station
1
WK(1)
PK(1)
Station
2
WK(2)
Station
i
PK(2)
WK(i)
PK(i)
Intro-To-Lean
Station
i+1
Station
N+1
PK(N)
Raw materials
inventory
14
11
Semi-finished
parts
11
12
Semi-finished
parts
Finished
goods
7
Station 3
RM
Station 1
RM
11
Station 2
RM
8
WK
PK
13
WK
4
PK
PK
11
13
WK
2
10
6
Material
handler
Intro-To-Lean
Order
receiving
Intro-To-Lean
Future State
Intro-To-Lean
Intro-To-Lean
Hybrid Systems
Intro-To-Lean
Intro-To-Lean
disciplines of lean
3. Perform PQR (product-quantity-routing) analysis
4. Identify value streamsselect a value stream
5. Calculate model line takt time
6. Value stream map the model lineassemble current state
map
7. Balance the lineassign standard work
8. Establish standard WIP (inventory levels)
9. Test the system (virtual cell)document results
10. Setup reduction event
Intro-To-Lean
Gary Conner, President of Lean Enterprise Training, Newport, OR, Road Map to
Lean for the Smaller Shop, Society of Manufacturing Engineers, Lean
Manufacturing 2007, Supplement to Manufacturing Engineering, 2007.
pp. 27-29.
Intro-To-Lean
References
Intro-To-Lean