LEAN MANUFACTURING

Content
 What is Lean Manufacturing?
 History
 Keys to Lean Success
 Comparison Between Traditional and Lean
Manufacturing
 Principle
 Benefits
 Why Lean Manufacturing Fails
 Barriers
 Lean Manufacturing Cycle
 Conclusion
What is Lean Manufacturing?

 "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.“
KEYS TO LEAN SUCCESS

 Prepare and motivate people

 Employee involvement
 Share information and manage expectations
 Identify and empower champions, particularly
operations managers
 Atmosphere of experimentation
COMPARISON BETWEEN TRADITIONAL AND LEAN
MANUFACTURING

 For years manufacturers have created products in

anticipation of having a market for them.
Operations have traditionally been driven by sales
forecasts and firms tended to stockpile inventories
in case they were needed.
 Lean organizations are capable of producing high-
quality products economically in lower volumes
and bringing them to market faster than mass
producers.
Principles of Lean
Principles of Lean
 Specify value from the standpoint of the end customer
by product family.
 Identify all the steps in the value stream for each
product family, eliminating whenever possible those
steps that do not create value.
 Make the value-creating steps occur in tight sequence
so the product will flow smoothly toward the customer.
 As flow is introduced, let customers pull value from
the next upstream activity.
 As value is specified, value streams are identified,
wasted steps are removed, and flow and pull are
introduced, begin the process again and continue it
until a state of perfection is reached in which perfect
value is created with no waste.
Benefits

 Reduced scrap and waste

 Reduced inventory costs
 Cross-trained employees
 Reduced cycle time
 Reduced obsolescence
 Lower space/facility requirements
Benefits…
 High quality & reliability
 Lower overall costs
 Self-directed work teams
 Lead time reduction
 Fast market response
 Longer machine life
Why Lean Manufacturing Fails

 Despite the enormous popularity of Lean, the track

record for successful implementation of the
methodology is spotty at best.
 Some recent studies say that failure rates for Lean
programs range between 50 percent and 95 percent.
 To analyze this level of performance from a Lean,
problem-solving perspective, continuous
improvement experts should be asking: Why do so
many companies fail to achieve Lean success?
Barriers
 Lack of resources
 Lack of expertise
 Initial high cost which includes the cost of resources as
well as expertise.
 Poor supply chain structure.- Ineffective training and
development of work force in the company
 Absence of continuous assessment of every individual in
the organization.
 Psychological factors such as fear of losing the job on
account of its implementation.
 Natural calamities.
7 wastes of lean manufacturing
Lean Manufacturing Cycle
Further Analysis Plan
 Comparative Case Study of Various Projects
Because of the diversity of task types, equipment and
other circumstances, a simple efficiency rate cannot
properly evaluate the movement of various workers.
 Improvement of Analysis Tool
As discussed earlier, measuring the exact distance of
the arbitrary movements of workers is not an easy job.
Finding a proper tool, such as computer software, will
improve the accuracy of analysis.
CONCLUSION

 “LEAN” can be said as adding value by eliminating waste

being responsive to change, focusing on quality and
enhancing the effectiveness of the work force.
 Although lean has its origin in the automobile industry
it is being successfully used in other production
industries. Lean manufacturing is now extended to fields
like I.T, service etc in order to reduce production cost
and meet changing customer needs.
 Since lean is completely customer oriented it is here to
stay. It is also important as it emphasis customer
satisfaction.
Thankyou