Lean Manufacturing

Awareness

History

History
Lean Manufacturing is sometimes
called the Toyota Production System
(TPS) because Toyota Motor
Companys Eiji Toyoda and Taiichi
Ohno are given credit for its
approach and innovations.

History

What is Lean?
Definition: It is the Systematic
approach of Identification &
Elimination of waste through
continuous improvement, focusing on
the flow of the product from raw
material to finished goods at the pull
of customer in pursuit of perfection.
Lean is
A business strategy that focuses on
the elimination of waste.
when we remove all the waste, we
are left with value.
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What is Flow?
Definition: Flow in manufacturing is
the movement of material through a
production system, with no
interruption at a rate equal to
customer demand.

What interrupts Flow?

Unevenness,
Mura

Overburden,
Muri
Waste
Muda
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Unevenness (Mura)
Variations in production volumes
driven by poor planning and
scheduling.

This creates the wastes

of unnecessary material
handling, overproduction,
waiting, and inventory.

Overburden (Muri)
Overburdening happens when a
machine or worker is pushed beyond
the natural limit of capacity.
Overburdening people
results in safety, ergonomic,
and quality problems
(motion and correction).
Overburdening machines
is a direct cause of
breakdowns and defects.
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Waste (Muda)
Elements of production that add time,
effort, cost, but no value.

Waste is really a symptom

and not a root cause of the
problem.
Waste points to problems
within the system.
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7 types of Waste (TIMWOOD)

TRANSPORTATION:
Any movement of material
that does not directly support
a synchronous system

INVENTORY:
Any supply in excess of
process requirements
necessary to produce goods

MOVEMENT:
Any movement of people or
machines which does not
contribute value to the product
or service

WAITING:
Idle time that is produced
when two dependent variables
are not fully synchronized

OVERPRODUCTION:
Producing more than needed
Producing faster than needed

OVER PROCESSING:
Effort which adds no value
to a product or service.
Enhancements which are
transparent to the customers,
or work which could be
combined with another
process

DEFECTS:
Rework of a product or
service to meet customer
requirements

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Transportation
Transportation
Transportation in term of loads and distance
travelled
Results :
Loss of traceability
Damaged goods
Increased Lead Time
Excess Costs
Storage space
Caused by:
Poor parts storage
Poor Work area layouts
Working ahead of build requirements
Lack of JIT/ Pull system
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Inventory
Inventory
Unnecessary stocks due to untimely delivery, buffers for
abnormality, over-processing and over-production
Results of Excess Inventory:
requires space
costs money and ties up capital
search and transport damage
hides defects
excess WIP and finished out-of-date product
Increased deterioration
Caused by:
Working ahead of build requirements
High WIP standards
No WIP standards
Lack of JIT/Pull system
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Inventory
Motion
Walking due to location of materials and works
Results :
Unnecessary walking
Poor ergonomic conditions
Part transfer
Reaching and stopping and walking to
locate/ pick up parts/tools
Caused by:
Poor parts placement
Poor process flow
Poor work station layout

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Inventory
Waiting
Idle time, usually due to waiting for machine to complete cycle,
material not delivered on time etc.
Results :
Over Production
Over Processing
Idle resources
Non-Value added work
Caused by:
Line stops
Waiting for Material
Repair/Maintenance
Waiting for equipment to process
Missing tools
Non- Full work process
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Inventory
Over Production
Over- producing, hence the inventory of final stock goes up, it needs
additional space to store them, and it make tracing of stock and quality
very difficult.
Results :
Products being produced in excess quantities
Products being made before customers need them
Excess Inventory
Excess Transportation
Hides available capacity
Caused by:
Working ahead of customer
(internal/external) or process requirements

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Inventory
Over Processing
Over- processing ahead of required, this is very visual when inventory
piling up long before it needed for next process.
Results :
Increased Processing Time
Costs
Incorrect process/equipment
Caused by:
Refining the product in ways or areas not
important to the customer
Wait Time
Unclear Quality Standards

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Inventory
Defect/Rework/Repair
Producing defect, if this is not eliminated, the cost will go up because of
wastage in materials, process labour and the labour to repair and tracking.
Results :
Customer Dissatisfaction
Non-Value added work
Extra costs
Extra space
Extra inspections/checks
Caused by:
Scrapped parts
Wrong or defective tools or machines
Wrong or missing processes
Poor Problem Solving
Unclear Standards
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 Once you learn how to see flow or

waste it becomes hard not to see it.

However, you need to learn how to see it first

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How to Identify Waste?

Go See
(Gemba)
Observe the
Workplace

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Approach

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Toyota Production System

House of
Toyota
GOAL: Highest Quality, Lowest Cost, and Shortest
Lead Time

Just-in-Time

Jidoka

Continuous
Flow

Stop and
notify
of
Separate
abnormalities
mans work
and
machines
work

Takt Time
Pull System

Heijunka
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Standardized
WorkStabilit
y

Kaizen

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Thank you