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    Lean Manufacturing Principles

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    Pavithra
    The document discusses the principles and goals of Lean manufacturing. It defines Lean as a systematic approach to identifying and eliminating waste through continuous improvement. The goals of Lean are zero defects, 100% value-add, lot size of one, and pulling from customer demand. Lean aims to improve customer satisfaction, increase profits, ensure long-term success, and create a competitive advantage through principles like specifying value, optimizing value streams, enabling flow, and pursuing perfection. The document outlines where Lean has been successfully implemented and how to develop a Lean factory and production system.

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    Lean Manufacturing Principles

    Uploaded by

    Pavithra
    259 views14 pages
    The document discusses the principles and goals of Lean manufacturing. It defines Lean as a systematic approach to identifying and eliminating waste through continuous improvement. The goals of Lean are zero defects, 100% value-add, lot size of one, and pulling from customer demand. Lean aims to improve customer satisfaction, increase profits, ensure long-term success, and create a competitive advantage through principles like specifying value, optimizing value streams, enabling flow, and pursuing perfection. The document outlines where Lean has been successfully implemented and how to develop a Lean factory and production system.

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    Lean

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    3)Lean

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    The document discusses the principles and goals of Lean manufacturing. It defines Lean as a systematic approach to identifying and eliminating waste through continuous improvement. The goals of Lean are zero defects, 100% value-add, lot size of one, and pulling from customer demand. Lean aims to improve customer satisfaction, increase profits, ensure long-term success, and create a competitive advantage through principles like specifying value, optimizing value streams, enabling flow, and pursuing perfection. The document outlines where Lean has been successfully implemented and how to develop a Lean factory and production system.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    259 views14 pages

    Lean Manufacturing Principles

    Uploaded by

    Pavithra
    The document discusses the principles and goals of Lean manufacturing. It defines Lean as a systematic approach to identifying and eliminating waste through continuous improvement. The goals of Lean are zero defects, 100% value-add, lot size of one, and pulling from customer demand. Lean aims to improve customer satisfaction, increase profits, ensure long-term success, and create a competitive advantage through principles like specifying value, optimizing value streams, enabling flow, and pursuing perfection. The document outlines where Lean has been successfully implemented and how to develop a Lean factory and production system.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 14

    LEAN

    MANUFACTURING
    PRINCIPLES
    Defining Lean
    Lean is:

    “A systematic approach to identifying and eliminating waste

    (non-value added activities) through continuous improvement by

    flowing the product at the pull of the customer in pursuit of

    perfection.”
    Lean Goals

     Zero Defects
     100% Value – add
     Lot Size of One
     Pull of the Customer
    Why Become Lean?

    • Improve Customer Satisfaction

    • Increase Sales and Profits

    • Insure Long-term Health of Company

    • Survival

    • Create Sustainable Competitive Advantage


    Key Principles of Lean Thinking

     VALUE - what customers are willing to pay for

     VALUE STREAM - the steps that deliver value

     FLOW - organizing the Value Stream to be continuous

     PULL - responding to downstream customer demand

     PERFECTION - relentless continuous improvement (culture)


    Where has Lean been successfully
    implemented?
    •Manufacturing
    Automotive
    Industrial Products
    Furniture
    Textiles and Apparel
    Printing and Packaging
    Consumer Products
    •Service Industries
    •Military
    •Healthcare
    Developing a Lean Factory
    The Goal and Getting There from Here
    •The Goal - Lean Throughout the Entire Enterprise
    •Set Aggressive Improvement Goals
    •Measurements of Existing Operations
    •Recognize Current Problem Areas
    •Apply the Lean Production System Concepts
    •Commit to the Continuous Improvement Process
    •Just do it!
    Value Added/Non-value Added
     Value-added:
     ANY ACTIVITY THAT PHYSICALLY CHANGES THE MATERIAL
    BEING WORKED ON (not rework/repair!)

     Machining Knitting
     Drilling Spreading/Cutting
     Assembly Dying
     Painting Sewing

     Non-value added:
     ANY ACTIVITY THAT TAKES TIME, MATERIAL, OR SPACE
    BUT DOES NOT PHYSICALLY CHANGE THE MATERIAL
     Sorting Stacking
     Counting Checking
    Lean = Eliminating the waste
    Value
    added
    8 Wastes
    5%  Overproduction
     Excess inventory
     Defects
     Non-value added
    processing
     Waiting
     Underutilized
    people
    Non-value  Excess motion
    added  Transportation

    Typically 95% of Total Lead Time is Non-Value Added!!!


    Lean Production System
    Goals - highest quality, lowest cost, shortest lead times
    Involvement Jidoka
    Just-In-Time
    •continuous flow •separate man &
    •takt time/pace machine work
    •pull system •identify abnormal
    •triggers conditions
    •poka yoke

    Kanban Standardized Work Kaizen

    Stable Manufacturing Process


    Toyota’s Lean Philosophy
    • Customer first
    • People are the most valuable resource
    • Kaizen (continuous improvement)
    • Shop floor focus
    Keys To Success
     Focus on the goal – eliminate waste!
     Gather baseline information and measure results
     Get everyone involved
     keep it simple
    Milk Run Concept

    Customer End

    Supplier End
    Thank you

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