Victora Tool Engineers Pvt. LTD.: Department: Quality Prepared By: Rakesh Kumar

Victora tool engineers pvt. Ltd.
3M
Department: quality Prepared by: rakesh kumar

Overview of lean Manufacturing
Lean Manufacturing System is a systematic approach to

identifying and eliminating waste (non-value added
activities) through continuous improvement by flowing
the product only when the customer needs it (called
“pull”) in pursuit of perfection.
Just-In-Time Quality
Material
Synchronization
Developer of lean concept
• Lean originates from the work of Taichi Ohno who was

looking to create effective production processes at Toyota
after the Second world war
• The fundamental principle is the elimination of all forms of
waste (or MUDA)
• Initially adopted by other Japanese companies it took some
time to reach the West and is know by various names (eg
Toyota Production System (TPS), Just-In-Time (JIT), etc)
• Lean’s systematic focus on the removal of waste is now being
applied across many industrial sectors
Waste is worse than theft!-Taichi Ohno

Benefits of lean manufacturing
• Increase Manufacturing capacity, efficiencies, throughput

• Manufacturing process improvements
• Manufacturing operational improvements
• Improve Labor Utilization
• Reduce direct and indirect labor costs
• Reduce Manufacturing Cycle-time From order receipt to
shipment From weeks to days
• Reduce inventories
• While increasing customer service and satisfaction levels
• Improve Bottom-line
• Improve cash flow, net income
comparison
Types of waste
Waste can be categorized in three categories:

• MUDA: WASTE (Ex. Variation, Excess cycle time,
Transportation, Waiting time, Inventory, Defects,
Inadequate capacity utilization )
• MURA: Irregularity, Inconsistency
• MURI: Strain, Inconvenience
muda
Muda is a Japanese term, it refers to non-value added tasks

(tasks which are wasteful and do not add any value). Muda can
be further broken down into 2 types:
Type I Muda :
• Non value added tasks which are essential under current
conditions. These tasks must be performed because:
• Current processes or systems require the tasks to be
performed.
• Processes or systems require re-design
• There is a specific regulatory requirement
• There is a specific customer requirement.
Cont…
Type II Muda: Non value added tasks which can be eliminated

immediately. The following seven wastes identify and classify
resources, which are commonly wasted. Toyota’s Chief Engineer,
Taichi Ohno as part of the Toyota Production System, identified
them.
• Transportation
• Inventory
• Motion
• Waiting
• Overproduction
• Over processing
• Defects
Transportation
Each time a product is moved it stand the risk of being

damaged, lost, and delayed, etc. as well as being a cost
for no added value.
This may appear unnecessary
but does add value. Large
transport is easily identified
but small transport such as
manual labour may not be so
noticeable. These can be
improved by changes to the
work environment.
inventory
• Inventory be it in the form of raw materials, work in

progress or finished goods, represent a capital outlay
that has not yet produced an income either by the
producer or for the customer. Any of these three items
not been actively processed to add value is waste.
• Carrying stock attracts cost
& storage problems.
Storage leads to stacking,
racking, sophisticated
computers, bar coding &
automation, all for an
activity that adds no value
to the product.
motion
• As compared to transportation, motion refers to the

producer or worker or equipment. This has significance
to damage, wear, safety. It also includes fixed assets and
expenses incurred in the production process.
• Typically, single handed operations
where both should be used, stretching
unnecessarily or awkwardly and
walking between things. All of these
take time or use time poorly, none add
value.
waiting
• Refers to both the time spent by the workers waiting

for resources to arrive, the queue for their products to
empty as well as the capital sunk in goods and
services that are not yet delivered to the customer.
• Typically, waiting for products
& services from preceding
operations, waiting for work
from their previous set-up or
waiting for cycles to finish, or
meetings to start.
overproduction
• Overproduction is the production of items before they

are actually required. Overproduction must be stored,
managed and protected.
• Producing more than is
needed hides a multitude of
problems. Excessive set-up
times, machine faults, risk of
producing obsolete stock.
Over processing
• Using a more expensive or otherwise valuable

resource than is needed for the task or adding features
that are designed in but unneeded by the customer.
• Adds cost but no value - e.g.
trimming & moulding to a
level that is beyond the
required standard adds extra
time that customers do not
want to pay for.
defects
• Quality defects prevent the customer from accepting

the product produced.
• Rejects are always produced
by systems and procedures
created by management. If
operators fail it is because the
process allowed them to fail
through inadequate training or
because the process was not
capable in the first place.
mura
Mura is Japanese term; it refers to performing tasks

which are irregular in nature. Such tasks are very
difficult to improve.
muri
Muri is Japanese term; it refers to excessive stress &

strain required to perform a task. Tasks should be
designed so that anyone can perform them.
Principle of lean manufacturing
Minimize material handling: Preference should be given to low or

no-cost solutions such as gravity-feed slides. Handle product once
only.
Minimize distances: Avoid walking, carrying, etc. by creating cells,
combining operations within a work center, better planning, and
soon.
Minimize strain: Work centers should be ergonomically designed to
avoid back and other muscle strains.
Minimize clutter: Everything should have a home, from parts and
tools at a workstation, to equipment and product within designated
floor spaces
Minimize storage: If you have the space, it will surely get filled.
Thus, continuously minimize your storage space for raw material,
Work In Progress, finished goods and spare parts throughout the
Cont…
Maximize utilization: Make optimal use of people, space, and

equipment to improve the return on investment.
Maximize flexibility: The key to lean is creating a layout that
can adapt quickly to changes in product, equipment or material.
Maximize smooth flow: Continuously determine and eliminate
the bottlenecks, then re-balance the line.
Maximize visibility: To quickly spot problems, maintain a clear
line of vision to anywhere, from anywhere.
Maximize communication: Lean requires constant training on
tools available to meet goals and objectives, and feedback on
how well things are going.
Example
Lean manufacturing tools
• JIT (Just in Time)

• TPM(Total productive maintenance)
• 5S
• Process optimization
• Visual Controls
• Streamlined layout
• Standardized work.
• Batch size reduction
• Point of use storage
• Quick changeover
• Pull and Kanban
Example
Cont…
Cont…
Cont…
Cont…
Cont…
Cont…
THANK-YOU

Victora Tool Engineers Pvt. LTD.: Department: Quality Prepared By: Rakesh Kumar

Uploaded by

Copyright:

Available Formats

Victora Tool Engineers Pvt. LTD.: Department: Quality Prepared By: Rakesh Kumar

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Victora Tool Engineers Pvt. LTD.: Department: Quality Prepared By: Rakesh Kumar

Uploaded by

Copyright:

Available Formats

Victora tool engineers pvt. Ltd.

Department: quality Prepared by: rakesh kumar

Lean Manufacturing System is a systematic approach to

• Lean originates from the work of Taichi Ohno who was

Waste is worse than theft!-Taichi Ohno

• Increase Manufacturing capacity, efficiencies, throughput

Waste can be categorized in three categories:

Muda is a Japanese term, it refers to non-value added tasks

Type II Muda: Non value added tasks which can be eliminated

Each time a product is moved it stand the risk of being

• Inventory be it in the form of raw materials, work in

• As compared to transportation, motion refers to the

• Refers to both the time spent by the workers waiting

• Overproduction is the production of items before they

• Using a more expensive or otherwise valuable

• Quality defects prevent the customer from accepting

Mura is Japanese term; it refers to performing tasks

Muri is Japanese term; it refers to excessive stress &

Minimize material handling: Preference should be given to low or

Maximize utilization: Make optimal use of people, space, and

• JIT (Just in Time)

You might also like