Lean manufacturing

Glossary
• Complacent – feeling so satisfied with your own
abilities or situation that you feel you do not need
to try any harder
• Overburden – to make someone or something work
too hard or carry, contain, or deal with too much
• Workload – the amount of work to be done,
especially by a particular person or machine in a
period of time
• Eliminating – to remove or take away someone or
something
• Workflow – the way that a particular type of work
is organized, or the order of the stages in a
particular work process
An overview of Lean
Manufacturing

• Lean is a methodology to reduce waste in a

manufacturing system without sacrificing productivity.
The customer defines what is of value in terms of what
they would pay for the product or service. Through lean
management, what adds value becomes clear by
removing or reducing everything that doesn’t add value.
History of Lean Manufacturing

• The idea of lean manufacturing was first

championed by the Toyota Production System
and called lean in the 1990s.
How to practice Lean
Manufacturing
Tools for lean manufacturing:

SMED (single-minute exchange of die, which is fast way to move from one
manufacturing process to another)

Value stream mapping

5S (a workplace organization methodology)

Poka-yoke (error-proofing)

Total productive maintenance (improves integrity and quality of

manufacturing process)

Rank order clustering (production flow analysis)

Single-point scheduling
Principles of lean
Some principles that are shared by both methods of lean
include:

Pull processing

Perfect first-time quality

Waste minimization

Continuous improvement

Flexibility

Building and maintaining a long-term relationship with

suppliers (learn more about vendor management)

Automation
Types of Waste in Lean
Manufacturing
Mura
• Unevenness, or waste due to
fluctuations in demand. This can
come from customer requests,
but it can also be due to an
organization adding new services
and thus additional work
Muri
• Overburden, or waste due to
trying to do too much at once.
This has to do with resource
allocation. When too few people
try to do too much work, they
often waste time switching from
on task to another

Muda
• Non-value-adding work, or
process waste. This waste comes
as a byproduct of something else.
Lean maximizes value, minimizes
necessary waste and removes
unnecessary waste altogether
Goals and Strategy of Lean
Manufacturing
Improve Processes must be designed to meet their
Quality expectations and requirements. Adopting total
quality management can make quality improvement
a priority

Eliminate Waste is bad for costs, deadlines and resources. It

Waste takes without adding any value to a product or
service

Reduce Reducing the time it takes to start and finish a

Time project is going to create value by adding
efficiencies.

Reduce Understanding the triple constraint is the first step

Total to understanding cost management
Costs
Thank you for attention!