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Lean Manufacturing

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Chris B

on 16 November 2014

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Transcript of Lean Manufacturing

Edited by:
Chris Buttacavoli
at TAC

Lean Manufacturing
What is Lean Manufacturing?
What is Lean Manufacturing?
What is Lean Manufacturing?
Creation of Lean:
Lean Manufacturing is the production control technique for eliminating the waste from your manufacturing while delivering quality products on time at least cost with greater efficiency.

The core idea is to maximize customer value while minimizing waste. Simply, lean means creating more value for customers with fewer resources.
It is a production system characterized by smaller batches, quick responses to customer demand, and smooth product flow.
Lean manufacturing is a management philosophy derived mostly from the Toyota Production System (TPS) (hence the term Toyotism is also prevalent) and identified as "Lean" only in the 1990s.
•Higher Quality production

•Reach customer satisfaction.

•Maximum utilization of resources

•Minimization of waste.

•Shorten lead times.

•Identify problems and communication between operations.
Principles to Lean Transformation
1. Deliver Value From your
Customer’s Perspective
Pull Systems
A pull system regulates the flow of resources in a manufacturing process. As a result, your business becomes increasingly lean, eliminating excess inventories of raw materials, work in process, and finished goods.

Customer orders drive production schedules based on actual demand and consumption rather than forecasting.

A pull system has the following advantages:
•Minimization of waste and obsolete stock.
•Flexibility to deliver customer demands quicker.
•Reduction in the need of working capital in a business.
2.Eliminate Waste
a) One Piece Flow
b) Takt Time
c) Zero defects
a) One Piece Flow
It is the opposite of batch production. Instead of building many products and then holding them in queue for the next step in the process, products go through each step in the process one at a time, without interruption. It improves quality and lowers costs.

One-piece flow helps to maximum utilization of resources, shorten lead times, and identify problems and communication between operations.
Lean Manufacturing Takt Time, it is how fast you need to manufacture product in order to fill your customer orders.

Takt Time is a key concept in lean manufacturing.

It is the heartbeat of a lean organization – matching actual production to customer demand. It is not a goal to be surpassed, but rather a target for which to aim:

•Producing faster than Takt Time results in overproduction – the most fundamental form of waste.
•Producing slower than Takt Time results in bottlenecks – and customer orders that may not be filled on time.
It’s a philosophy of Lean. It simply means that every process should be designed so that it is impossible to produce poor quality.
3.Continuous Process Improvement.
The term "continuous improvement" means incremental improvement of products, processes, or services over time, with the goal of reducing waste to improve workplace functionality, customer service, or product performance.
It is defined as the belief that an organization must constantly measure the effectiveness of its processes and strive to meet more difficult objectives to satisfy customers.
b) Takt Time
c) Zero defects
• What is Lean Manufacturing?

• Principles of Lean transformation

• Summary
Thank You For your Time and attention
Wishing you a Happy New Year
Pull Systems
1. Deliver Value From your Customer’s Perspective
2. Eliminate Waste
3. Continuous Process Improvement
Full transcript