Content

1. Introduction to lean manufacturing

What is lean manufacturing
consists of Lean operating system
2. Lean principle
3. Toyota production system
4. Kinds of waste
5. About the company
6. How to evaluate the lean manufacturing system
7. Process map
8. Fish-bone diagram
9. Management plan
10. Conclusion

1.Introduction
What is Lean manufacturing ?
Way of eliminating waste & improve efficiency in manufacturing
Derived from Toyota production system
Focus on elimination waste, flow & value stream
Doing more with less
Definition of Lean
It is a comprehensive set of techniques which when combined
allows you to reduce and eliminate the wastes.
This will make the company leaner, more flexible and more
responsive by reducing waste.

Introduction.
consists of Lean operating system
A lean operating system follows certain principles to deliver value to the
customer while minimizing all forms of loss.
Each value stream within the operating system must be optimized
individually from end to end.
Lean tools and techniques are applied selectively to eliminate the three
sources of loss: waste, variability and inflexibility.

2.Lean Principles
1. Accurately specify value from customer perspective for both products and
services.
2. Identify the value stream for products and services and remove non-valueadding waste along the value stream.
3. Make the product and services flow without interruption across the value
stream.
4. Authorize production of products and services based on the pull by the
customer.
5. Strive for perfection by constantly removing layers of waste.

3.Toyota production System

After World War II, Toyota was almost bankrupt.
Post war demand was low and minimising the cost per unit
through economies of scale was inappropriate. This led to
the development of demand-led pull systems.
The Japanese could not afford the expensive mass
production facilities of the type used in the USA so they
instead focused on reducing waste and low cost automation.
Likewise, Toyota could not afford to maintain high inventory
levels.

Toyota production System.

Founders of the Toyota Production System (TPS)

Taiichi Ohno
(1912 1990)

Shigeo
Shingo
1909 1990

4.Kinds of wastes
1. Overproduction
2. Waiting

3. Unnecessary Transport
4. Over processing
5. Excess Raw Material
6. Unnecessary Movement
7. Defects
8. Unused Employee Creativity

6.How to evaluate lean manufacturing

Collecting data from the Factory.
Analysis the process by using Process mapping.
Process Mapping is a method for depicting a process, material or
information flow in a diagrammatic form. It is visually represents the work process,
Identifies problem areas opportunities for improvement ,easily understand the process
before improving it.
Choose the weak link /area/ critical process that to be improved.
Detail analysis by using Fish Born Diagram.
A fishbone diagram called as cause and effect. It is a visualization tool for
categorizing the potential causes of a problem in order to identify its root causes.

 Identify the Key Performance Indices relevant to the

area selected.
KPI is a set of quantifiable measures that a
company or industry uses to gauge or compare
performance in terms of meeting their strategic and
operational goals.

Prepare a Management Plan, Identifying tasks to

achieve above defined KPIs

7. Process Map
FABRIC
INSPECTION
SPEADING
CUTTING

QUALITY
CHECK

FOLDING

BUTTONING

PINNING

THREAD
TRIMMING

PACKAGING

BUNDLING

IRONING

CUTTING
AUDIT

QUALITY
CHECK

PREPARATORY

FOLDING

QUALITY
CHECK

ASSEMBLY

PACKING

SHIPMENT

Human Resources
Loosing of getting
better idea
Law skilled labor

Transport

Need a long drive for

the shipment

Methods

Arrange methods in
lines for easy monitoring
like C and U methods of
arrange

unmatched workers

Manual methods use for

loading

need of large transport

trucks
Need large area for
parking facilities
Disposal of damage
garments

Loading

Material

Specific and right size

machine
Proper lubricating
Cleaning and
maintenance
Machine

Management planes
Activity

Implementation Method

Transport

using big trucks for transports

Construct special section for transports

Human resources

Place matched workers in the line

Give proper training for them
Recruitment of qualified employees

Methods

Introduce new machine for loading and unloading

Using C and U methods for the arrangement of lines
Introduce new dust remover to the working
environment

Machine efficiency

Cleaning and lubricant the machines

Material

Employee employers to the storage section

Conclusion
According to my view improving those weak link area
using proper management planes applying lean
manufacturing concept they can achieve more
efficiency than now

Thank You