Manufacturing?”
• Lean manufacturing is aimed at
elimination of waste
• Organize processes to add value to
the customer
• Deliver goods “just-in-time”
• Service organizations also using
lean
Basic Lean Principles
• Add nothing but value
– Eliminate “muda” – waste
• Do it right the first time
• People doing the work add value
– Team oriented
• Deliver on demand
– “Pull” instead of push
History of Lean
• “The Machine That
Changed the
World”
• Toyota auto
manufacturing
• “Value chain”
Waste Categories
• Overproducing
• Inventory
• Waiting
• Extra Processing
• Correction
• Excess Motion
• Transportation
• Underutilized
People
OVERPRODUCIN
G
To producer sooner, faster
or in Greater quantites than
customer demand.
INVENTOR
Y
RAW MATERIAL WORK IN
PROGRESS OR FINISHED
GOODS WHICH IS NOT HAVING
VALUE ADDED TO IT.
INVENTOR
Y
WAITING
PEPOLE OR PARTS THAT
WAIT FOR A WORK CYCLE TO
BE COMPLETED.
WAITING
TRANSPORTATIO
N
UNNECESSARY MOVEMENT
OF PEOPLE ,PARTS OR
MACHINES WITHIN A PROCESS.
REWORK
Non right first time
,Repetition or correction of a
process.
OVER
PROCESSING
Processing beyond the
standard required by the
customer.
8th WASTE
Potential of people
Flow Process Charts for Data Recording
This chart uses This chart is of 3 types:
circles for operations Man – Activities of operator
arrows for transports machine - Manner in which the
squares for inspections equipment is used
triangles for storage Material - the changes the material
letter D for delays. undergoes in location or condition
Before Layout Revision Process
Sl.
Operation M achine
No
.
From In
After Layout Revision Process
1 Storage
trolley Sl.
Operation Machine
2 Coining Press No.
Storage + Relief In
3
Plug Assy.
Trolley 1 Storage
trolley
4 Ball Pressing Press
2 Coining Press
On the
5 Storage
Machine
3 Bearing Pressing Press
6 Leak Check Air Gauge
12 Storage --
Total 6 6 0 1 4
Vertical lines connect these symbols in the sequence they are performed.
BEFORE
Before Layout Revision Process
Sl.
No Operation M achine
.
From In
1 Storage
trolley
2 Coining Press
Storage + Relief
3 Trolley
Plug Assy.
On the
5 Storage
M achine Storage - 6
6 Leak Check Air Gauge Process - 6
7 Storage Table
Inspection - 1
Poppet
Waiting - 4
8 Table
assembly
Bearing
9 Press
Pressing
10 Storage Table
Thrust washer
11 Poka-Yoke
Assy.
12 Storage --
Total 6 6 0 1 4
inspection
storage
operation waiting
transportation
AFTER
After Layout Revision Process
Sl.
Operation Machine
No.
In
1 Storage
trolley
2 Coining Press
Storage - 1
Process - 5