2. • Lean refers creating more value for customers
through identifying, eliminating or reducing
waste.
• Lean is a way of thinking. It it is all about
continuous improvement with a focus on
eliminating all forms of waste in a process.
What is Lean?
Customer
value
3. • Value is A capability provided to a customer at
the right time at an appropriate price, as defined
by the customer.
•Cost
•Quality
•Delivery
What is value?
4.
5. • Lean is systematic approach to identify and eliminating
the waste (non value activities) through continuous
improvement.
Lean manufacturing
6. • Lean Manufacturing is all about making a product
in the most efficient and effective manner, while
looking for ways to continuously improve.
• Continuous Improvements:
– Decrease Cycle Time
– Eliminate sources of waste in a process
– Increase Throughout
Continued…..
7. what makes a manufacturing system Lean?
The 3 m’s of lean
Muda____Waste
Mura____Inconsistency
Muri___unreasonableness
8.
9.
10. • 1950 to 1890
• Eli Whitey is most famous for perfection of interchangeable
parts. Whitney developed this about 1799.
• As production system or system changed; few people
concerned themselves with:
What happened between processes?
How multiple processes where arranged within the factory?
How each worker went about a task?
This changed in the late 1890’s with the work of early
industrial engineers.
History of lean management
11. • Prepare power point on the following history of
lean management.
– 1850-1890--- Eli Whitney
– 1878--frederick W. Taylor
– 1904—Frank Gilbreth
– 1908—Henry Ford
– 1945 to 1970 ---Ishikawa, Edwards Deming
– 1949 to 1975--- Shigo, ohno
– 1980—Omark industries , & Kawasaki
– 1990 to today---industrial engineers
Assignment 1
12. • Lean provides tangible benefits
• Reduces costs not just selling price
– Reduces delivery time, cycle time, set-up time
– Eliminates waste
– Seeks continuous improvement
• Improves quality
• Improves customer ratings and perceptions
• Increases overall customer satisfaction
• Improves employee involvement, morale, and
company culture
• Helps “transform” manufacturers
12
Benefits
13. Toyota Production System (TPS)
• Quality, Cost, Delivery
– Shorten Production Flow by
Eliminating Waste
• Just In Time
– The Right Part at the Right Time in
the Right Amount
– Continuous Flow
– Pull Systems
– Level Production
• Built-In Quality
– Error Proofing – Poka Yoke
– Visual Controls
• Operational Stability
– Standardized Work
– Robust Products & Processes
– Total Productive Maintenance
– Supplier Involvement
15. • The Japanese word for waste is muda, which is
defined as “uselessness.”
• Lean tools are designed to reduce Muda in
organizations and improve quality control.
• In other words, Lean tools seek to eliminate
processes that aren’t valuable.
What Are Lean Tools?
16.
17. Lean Tools Summary
Bottleneck Analysis Structured way of looking at workflows
Just-in-Time (JIT) On-demand system of production
Value Stream Mapping Analyzing and optimizing a process
Overall Equipment Effectiveness
(OEE)
Measure of productive time
Plan-Do-Check-Act (PDCA) Method to manage change
Error Proofing Analysis tool based on prevention
Root Cause Analysis (RCA) Method to get the foundation of an issue
