What Is Lean Manufacturing? Prepared By: Mr. Abdul Latif Asst. Manager.QA MTM Faisalabad Pakistan

2. Lean Manufacturing….

3. AGENDA
1- What Is Lean Manufacturing?
2- Waste & Types Of Waste
3- Toyota Production System
4- Key Techniques For Lean Manufacturing
5- Five- S
6- Benefits Of Lean Production
7- Lean Examples
8- How People Benefit From Lean?
9- Questions & Answers

4. A way to
“Eliminate Waste”
“Improve Efficiency”
in a manufacturing process.
What Is Lean Manufacturing?

5. What Is Waste?
Waste is anything that
happens to a product /
service that
“Does Not Add Value”
from the customer’s
perspective.

6. Non-Value-Added: Hold all waste in a
“CLOSED MITT”
Value Added
Types Of Waste?
Complexity
Labor
Overproduction
Space
Energy
Defects
Materials
Idle Materials
Transportation
Time

7. • Complexity
• Labor

8. • Overproduction
• Space

9. • Energy
• Defects

10. • Materials
• Idle Materials

11. Inventory Hides Problems

12. Less Inventory Exposes Problems

13. •Transportation
•Time

14. TOYOTA PRODUCTION SYSTEM
The Toyota Production System was developed by Sakichi Toyoda, Taiichi Ohno in the late 1940’s.
The focus of the Toyota Production System is the elimination of waste. Toyota identified 7 Wastes to
be eliminated, and then developed a wide range of techniques and practices for eliminating these
wastes.
The core of the Toyota Production System is its focus on
 Respect For People
 Continues Improvement
 Commitment To Its Long Term Philosophy.
 Eliminate Waste.
Toyota implemented a number of techniques to create a culture of change. This includes empowering
employees to eliminate waste, which results in
 Faster Lead Times,
 Better Quality
 Lower Costs.
These improvements led to many companies copying the techniques adopted by Toyota. Some
companies focused on the lead time and inventory reduction techniques and implemented Just in
Time.

15. Key Techniques For Lean Manufacturing
 5 S
 Single Minute Exchange of Dies
(SMED)
 Kanban
 Cellular Manufacturing

16. FIVE-S

17. Before 5S

18. After 5S

19. Bad Example
Good Example

20. Good Example
Bad Example

21. Bad Example
Good Example

22. Benefits Of Lean Production
 Greater Flexibility
 Simplified Scheduling & Controlled Activities
 Better Use Of Human Resources
 More Product Variety
 Reduced Inventory
 Improved Quality
 Lower Costs
 Reduced Space Requirements
 Shorter Lead Time
 Increased Productivity

23. Lean Examples

24. Lean Examples

25. Lean Examples

26. Lean Examples

27. Lean Examples

28. How People Benefit From Lean?
Element Traditional Lean
Communication Slow & Uncertain Fast & Positive
Teamwork Inhibited Enhanced
Motivation Negative, Extrinsic Positive, Intrinsic
Skill Range Narrow Broad
Supervision Difficult and
Fragmented
Easy & Localized

30. Thanks