Lean Management: Learning Objectives
Lean Management: Learning Objectives
Lean Management: Learning Objectives
Management
An Introduction
Naeem Shahzad
PIQC Institute of Quality
Learning Objectives
• Understand the basics of Lean Manufacturing
• Understand different types of wastes
• Understand concepts of Lean tools
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1 Fundamentals of
Lean Manufacturing
What Is Lean Management?
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What Is Lean Management?
all the resources used in the various activities of the enterprise. It involves
What Is Lean Management?
principles and practices to reduce cost through the relentless removal of waste
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What Is Lean Management?
Lean
Manufacturing
Toyota
Production
System
Toyota
Production
System
Womack
Mass
Production 1980s
Shingo
Scientific
Management
Toiichi Ohno 1950s
1908
Taylor
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1880s
What Is Lean Management?
International Motor Vehicles Program (IMVP)
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Objectives of Lean Management?
Objectives of Lean Management ?
Lean Supply Chain strive to achieve following;
• Eliminate waste in business value streams
• Meet Customer demand
• Increase velocity
• Reduce need for working capital
• Increase inventory turns
• Gain market share
• Increase profitability
• Develop workforce
• Produce with perfect quality
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5
Types of waste
“Any activity that does not value to the good or service in the eye of the
customer.”
A by‐product of a process or task with unique characteristics requiring special
management control.
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Types of waste: Toyota 3M Model
Toyota’s view is that the main method of Lean is not the tools, but the reduction of
three types of waste:
• Muri
Overburden
• Mura
Unevenness
• Muda
Non‐value‐adding work
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Types of waste: Toyota 3M Model
• Muri
Overburden
• Mura
Unevenness
• Muda
Non‐value‐adding work
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Types of waste: Muda
Toyota’s Taiichi Ohno
originally defined seven types
of wastes;
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7
Types of waste: Muda
Overproduction
Overproduction is building something before you can ship it to the next process
or someone in exchange for cash.
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Types of waste: Muda
Waiting
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Types of waste: Muda
Transportation
Moving work in process (WIP) from place to place in a process, even if it is only
a short distance. Or having to move materials, parts, or finished goods into or
out of storage or between processes.
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Types of waste: Muda
Inventory
Many companies order over & above what is required to fulfill the order, this
may be due to quality problems along the production process or the often
mistaken belief that is saves money by ordering larger quantities.
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9
Types of waste: Muda
Motion
Any motion employees have to perform during the course of their work other
than adding value to the part, such as reaching for, looking for, or stacking
parts, tools, etc. Also, walking is waste.
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Types of waste: Muda
Overprocessing
Taking unneeded steps to process the parts. Inefficiently processing due to poor
tool and product design, causing unnecessary motion and producing defects.
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Types of waste: Muda
Defective Units
Production of defective parts or correction. Repairing of rework, scrap,
replacement production, and inspection means wasteful handling, time, and
effort.
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Types of waste: Muda
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Lean Principles
Leans Principle Implications for Supply Chain Management
1. Create Value for
the Customer
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Lean Principles
Leans Principle Implications for Supply Chain Management
2.Identify all steps
across a value
stream
A value stream encompasses all “the
processes of creating, producing and
delivering a good or service to the market.”
All of the activities that are performed to
process raw material to finished product,
from order to cash and from product
concept to product launch, are included.
Identifying steps across the entire value
stream often exposes waste.
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Lean Principles
Leans Principle Implications for Supply Chain Management
3. Create Value flow
What are the actions that create value flow?
One piece or continuous, smooth flow is the
ultimate objective. When striving for
smooth flow, problems that must be dealt
with become visible.
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Lean Principles
Leans Principle Implications for Supply Chain Management
4. Pull products based
upon customer
demand
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Lean Principles
Leans Principle Implications for Supply Chain Management
5. Strive for perfection by
continually removing
successive layers of waste
Relentless continuous improvement
removes successive layers of waste.
Continuous improvement results are
maximized when the first four lean
principles are in place.
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2 Lean Manufacturing
Flow Mapping
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Manufacturing Strategies
The following strategies are used for manufacturing to delivery items to
the customer;
• Engineer‐to‐Order (ETO)
• Make‐to‐Order (MTO)
• Assemble‐to‐Order (ATO)
• Make‐to‐Stock (MTS)
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Manufacturing Strategies
Key Metrics: Time
Delivery Lead Time
Engineer‐to‐
Design Purchase Manufacture Assemble Ship
Order
Delivery Lead Time
Make‐to‐
Inventory Manufacture Assemble Ship
Order
Delivery Lead Time
Assemble‐to‐
Manufacture Inventory Assemble Ship
Order
Delivery Lead Time
Make‐to‐
Manufacture Assemble Inventory Ship
Stock
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Value Stream Mapping
Flow
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Value Stream Mapping: Process Flow Chart
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Value Stream Mapping: Process Flow Chart
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Value Stream Mapping
Value Stream Mapping is
a Lean technique used
to analyze the flow of
materials and
information currently
required to bring a
product or service to a
consumer.
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Value Stream Mapping
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Value Stream Mapping
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Value Stream Mapping
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Value Stream Mapping: Process Flow Chart
Exercise: Local Branch‐Loan approval
Key steps for loan approval are given below, starting from form filling till contract signing for loan.
1. Form filling: As customer requests for medium size loan, the bank representative takes about 45min (on
average) to retrieve the form and other related documents, as he also listens to other customers. After this
waiting time, customer takes 25min to fill the form and completes the other documentation requirement.
2. Documentation approval: Customer submits filled documentation; after review Bank representative
submits documentation to Branch Manager for approval. Documentation remains on the table for about
32hr before it is approved by Brach Manager who takes 5min to approve it.
3. Customer Profile Creation: Approved documents remain 1hr on Branch Manager’s table before they are
sent to IT executive in order to create customer profile. It takes about 27hr for approved documents profile
creation is started and completed in 12min.
4. Electronic Documentation: Once the customer’s electronic profile is created in the computer, (after 24hr) IT
executive takes about 4min to develop electronic documents to be sent to the head office.
5. Sending Documents: When all electronic documents are completed IT executive sends all electronic files to
head office after 2hr by just hitting the “Send to HO” (assume zero min).
Head Office: Electronic file is approved & processed by head office in 46min and sent back to the branch
office after 21 days.
6. Contract signing: Customer waits for about 110 min for formal contract singing which takes about 15min. 38
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Value Stream Mapping
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