lean manufacturing techniques (1)

23
LEAN MANUFACTURING TECHNIQUES Let’s Talk About Principles, Not About Tools…

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Page 1: Lean manufacturing techniques (1)

LEAN MANUFACTURING TECHNIQUES

Let’s Talk About Principles, Not About Tools…

Page 2: Lean manufacturing techniques (1)

Introduction to Lean Manufacturing

Kai = Change

Zen = Good

Change of betterment

Page 3: Lean manufacturing techniques (1)

Kaizen

Continuous Improvement Continual Improvement

Page 4: Lean manufacturing techniques (1)

Paradigm :The way you look at things

Shift = Change

Page 5: Lean manufacturing techniques (1)

Paradigm Shift

Page 6: Lean manufacturing techniques (1)

Gemba

Gemba – Real Place of work

Restaurant – Kitchen is real place of workManufacturing Company – Shop floor is real

place of workShopkeeper – Shop where exchange of

goods with customer.

Page 7: Lean manufacturing techniques (1)

Manufacturing

WhereverRaw material is converted

to finished products.

Page 8: Lean manufacturing techniques (1)

Process of ConversionRaw Material Finished Goods

Request for raw materialPotatoes are transported to gateGate supervisionTransport to quality divisionPotatoes are separated in batches for

supervisionSupervision for qualityTransport to storage areaPotatoes are stored in batchesTransport from Storage to Washing areaPotatoes are washed in batches thoroughly Remove from washing areaTransport to Pealing machine

Page 9: Lean manufacturing techniques (1)

Potatoes are pealed offTransport to slicing areaSettings are done for slicingPotatoes are slicedTransport to frying areaPotato slices are friedTransport to flavoring areaFlavors are added in proper amountTransport to packaging areaWafers are packed under maintained

conditionsTransport to distribution areasWafers packets are taken out of factory for

distributionFinal distribution

Page 10: Lean manufacturing techniques (1)

Traditional Cost Vs

Lean approach for Cost

Page 11: Lean manufacturing techniques (1)

Selling Price for Traditional Business

Cost of raw material +

cost of manufacturing +

Profit =

Selling Price

Page 12: Lean manufacturing techniques (1)

Selling Price for LEAN Way of Business

Profit =

Selling Price-

Cost of raw material -

cost of manufacturing

Page 13: Lean manufacturing techniques (1)

Did they add Value or Cost

Value: Wherever Physical or Chemical Property of Product is Changed for which customer is willing to pay

Page 14: Lean manufacturing techniques (1)

Process of ConversionRaw Material Finished Goods

Request for raw materialPotatoes are transported to gateGate supervisionTransport to quality divisionPotatoes are separated in batches for

supervisionSupervision for qualityTransport to storage areaPotatoes are stored in batchesTransport from Storage to Washing areaPotatoes are washed in batches thoroughly Remove from washing areaTransport to Pealing machine

CC

CC

CCCC

CCC

C

Page 15: Lean manufacturing techniques (1)

Potatoes are pealed offTransport to slicing areaSettings are done for slicingPotatoes are slicedTransport to frying areaPotato slices are friedTransport to flavoring areaFlavors are added in proper amountTransport to packaging areaWafers are packed under maintained

conditionsTransport to distribution areasWafers packets are taken out of factory for

distributionFinal distribution

VCC

V CV

CVC

VC

CC

Page 16: Lean manufacturing techniques (1)

Value Adding Ratio [VAR]

Value Adding TimeTotal Throughput Time

Where, throughput time is time taken for whole process

to get completed for single set/unit of product

Page 17: Lean manufacturing techniques (1)

VAR for different type of Organizations

Type of Organization

VAR (In %)

Traditional Organizations

0.1-1

Companies who have started Lean

(from 1-2 yrs)

5

World class companies

10

Very high level (e.g. Toyota Motors)

30

Page 18: Lean manufacturing techniques (1)

Japanese Terms

MudaMuraMuri

Page 19: Lean manufacturing techniques (1)

Any Questions??

Page 20: Lean manufacturing techniques (1)

Purpose of Kaizen

To identify, reduce and totally eliminate the

3M

Page 21: Lean manufacturing techniques (1)

Tools 5S (Workplace Management)VSM (Value Stream Mapping) JIT (Just-In-Time)SMED (Single Minute Exchange of Dies)KanbanCellular ManufacturingTPM (total Productive Maintenance.Six SigmaPoka yokeVisual Management (tool for creating

standards)

Page 22: Lean manufacturing techniques (1)

Any Questions??

Page 23: Lean manufacturing techniques (1)

Thank You