Technical Seminar On:

LEAN
MANUFACTURING
A BRIEF HISTORY OF LEAN MANUFACTURING

In 1900’s U.S. manufacturers like Henry ford

brought the concept of mass production. U.S.
manufacturers have always searched for
efficiency strategies that help reduce costs,
improve output, establish competitive position,
and increase market share.
Early process oriented mass production
manufacturing methods common before World
War II shifted afterwards to the results-oriented,
output-focused, production systems that control
most of today's manufacturing businesses.
 WHAT IS LEAN MANUFACTURING?
• Lean manufacturing is a manufacturing system
and philosophy that was originally developed
by Toyota, Japan and is now used by many
manufacturers throughout the world.
• Lean Manufacturing can be defined as:
• "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."
 WASTES IN MANUFACTURING

• The aim of Lean Manufacturing is the

elimination of waste in every area of
production including customer relations,
product design, supplier networks, and factory
management. Its goal is to incorporate less
human effort, less inventory, less time to
develop products, and less space to become
highly responsive to customer demand while
producing top quality products in the most
efficient and economical manner possible.
 WASTES IN MANUFACTURING
• 1 Overproduction
• 2 Waiting
• 3 Inventory or Work in Process (WIP)
• 4 Processing waste
• 5 Transportation
• 6 Motion
• 7 Making defective products
• 8 Underutilizing people
• ELEMENTS OF LEAN MANUFACTURING
• Those concepts that lead to the
implementation of lean manufacturing
successfully are called elements of lean
manufacturing. The basic elements of lean
manufacturing are waste elimination,
continuous improvement, pull system, one-
piece workflow, cellular manufacturing and
5S’s. When these elements are focused in the
areas of cost, quality and delivery, this forms
the basis for a lean production system.
 1. Elimination of waste

Waste is anything that doesn’t add value to the product. Seeing

whether the process is adding value to the product or not is
the best way to identify wastes.

Is the activity adding value?

If YES If NO

Is this the best way to do it? Ifnot, can it be

reduced? Can it be eliminated?

 
ELEMENTS OF LEAN MANUFACTURING

1. Elimination of waste

2. Continuous improvement

3. Pull system

4. One-piece flow

5. Cellular manufacturing

6 The 5 S’s
• Batch & Queue Processing
Process Process Process
A B C

10 minutes 10 minutes
10 minutes
Lead Time: 30+ minutes for total order
21+ minutes for first piece

• One piece flow

Process Process Process

A B C

12 min. for total order

3 min. for first part
  TRADITIONAL MASS
PRODUCTION
Production schedules are based Forecast — product is pushed
on… through the facility
Products manufactured to… Replenish finished goods inventory
Production cycle times are… Weeks/months
Manufacturing lot size quantities Large, with large batches moving
are… between operations; product is sent
ahead of each operation
Plant and equipment layout is… By department function
 
  Quality is assured… Through lot sampling
Workers are typically assigned… One person per machine
Worker empowerment is… Low — little input into how
  operation is performed
Inventory levels are… High — large warehouse of finished
goods, and central storeroom for in-
  process staging
Inventory turns are… Low — 6-9 turns pr year or less
Flexibility in changing Low — difficult to handle and
  manufacturing schedules is… adjust to
  Manufacturing costs are… Rising and difficult to control
LEAN PRODUCTON
Customer Order — product is pulled through
the facility
Fill customer orders (immediate shipments)
Hours/days
Small, and based on one-piece flow between
operations
By product flow, using cells or lines for product
families
100% at the production source
With one person handling several machines
High — has responsibility for identifying and
implementing improvements
Low — small amounts between operations, ship
often
High — 20+ turns per year
High — easy to adjust to and implement
Stable/decreasing and under control