When a student asks you to explain Lean Mfg, it requires a simple way of explaining. By giving examples, pictures and case studies, each Lean philosophy can be explained. Lean in the real Lean sense.

1. Jayesh C S Pai
General Manager
MSME Tool Room,
Kolkata

2. 10/5/2014 CSDO 2

3. 10/5/2014 CSDO 3

5. The Elephant is like …
10/5/2014 CSDO 5

8. 8
TODAY’S BUSINESS ISSUES:
Quality and price are two axis of business so long. The Third axis
emerged as -"THE TIME"- the factor taking leading position in business.
“SPEED" is the need of hour. “To be FAST and to be FIRST has become
the challenge".
Conventional Business approach is moving towards higher
production (Quantity), which some time affects the Quality and may force
to sell in discounts or as seconds, and to carry out "High Inventories“
“Quality in time" at the "least cost" is the mission statement,
moving ahead in this changing environment.
"Statistical Methodologies" -that study the uncertainties,
Analytical approach that economies the cost and which minimizes the
waiting time/ idle time through such “No investment”- “No cost tools”
enabled to maximize the return on valued resources.

9. 9
INNOVATING FOR COMPETITIVENESS
Innovation requires the planned abandonment of established,
familiar, customary or comfortable ways of working… whether in
product or services, competencies or human relationships or the
organisation itself.
Business
Assessment
Change
Management
Break through
Planning System
Strategic
Decision
Making
Conclusion: Innovation means that you must be organized to allow
constant change.

15. YamazumiAllows you to identify the waiting time
between jobs and processes.

16. 16
Example for takt time
Time Available Minutes
Shift 480
Breaks -10
Lunch -20
5S -10
Meetings -5
Changeover -220
Maintenance -5
Other -0
Total minutes 210
Total seconds 12600
Demand
Min 900
Avg 1080
Max 1800
Takt time (Min) = 12600
900
Takt time (Avg) = 12600
1080
Takt time (Max) = 12600
1800
Takt time
Min 14.0
Avg 11.7
Max 7.0

22. 5S Examples
Before After

27. Single Minute Exchange of Dies (SMED)
Method that focuses on the rapid conversion from
manufacturing one product to the next

28. SMED Examples

33. Poka-Yoke is a system that, after being implemented,
makes the creation of a defect in the manufacturing
process impossible to happen.

34. The Golden Zone is the prime area to have the
materials and tools necessary for our duties. To
reduce waste and improve ergonomics we should
focus on this area to perform the tasks.

35. Jidoka is a system, to install on a machine from the production
process, that allows the detection of defects in the machine and
the automatic shutdown of the system to avoid passing the defect
to the next process.

36. The Junjo system is divided into two categories, sequence and kit.
When the component to be supplied in the border of line is large,
or is a main component of the product, it must be provided in
sequence (example: the car seats).

37. The system originally adopted by the industry had as
fundamentals produce to sell (push system). With the
pull system, rather than "push" the product, is the client
that "pull" the entire production.

38. 38
Example for takt time
Time Available Minutes
Shift 480
Breaks -10
Lunch -20
5S -10
Meetings -5
Changeover -220
Maintenance -5
Other -0
Total minutes 210
Total seconds 12600
Demand
Min 900
Avg 1080
Max 1800
Takt time (Min) = 12600
900
Takt time (Avg) = 12600
1080
Takt time (Max) = 12600
1800
Takt time
Min 14.0
Avg 11.7
Max 7.0

39. 39

40. 40

41. 41
Eight wastes
Taiichi Ohno's original enumeration of the seven wastes plus
underutilized people. These are:
1. Overproduction: Making more, "earlier, or faster than the
next operation needs it.
2. Waiting for the next process, worker, material, information,
or equipment.
3. Transportation: unnecessary transport of materials.
4. Overprocessings of anything that does not add value.
5. Inventories more than the absolute minimum required to
meet customer demand.
6. Motion: unnecessary movement (like waiting) of people.
7. Production of defective parts or information.
8. Not fully utilizing employees brain power, skills,
experience, talents and creativity.

42. There are 7 wastes that we try to reduce and
eliminate when we implement Lean.

44. The translation for Andon is lantern, and it's a visual control to
"call for help" to the person in charge of resolving the abnormal
situation. He goes to the site and only when production resumes
its normal course the andon returns to green.

46. JIT (Just In Time) is a production system that aims to reduce the
WIP (Work In Process). As tools JIT uses Kanban and Junjo and
focus on continuous improvement, flow, the involvement of all and
quality.

50. 1st
Gen:
Fix It
when it
breaks
Focus:
Repair
Tasks
2nd Gen:
Scheduled O/H
Sys for Plng &
Controlling work
Focus: Improving
Maintenance
Planning &
Scheduling
4th Gen: Focus:
Failure
Elimination –
Pro Active
Maintenance,
LCC, Lean,
CBM+, RCA
3rd Gen:
CBM, FMEA, Multi
Skilling, Team Work,
Rel, Maint, Availb
Computers
Focus: Predicting,
Preventing & Avoiding the
Consequences of Equipment
Failures
1940 1950 1970 1990 2010
10/5/2014 CSDO 50

53. 10/5/2014 CSDO 53