History
Definition Process How does lean applicable Components of lean manufacturing. Why lean fails Live examples of lean
History
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1450- Arsenal in Venice was the first person to truly integrate an entire production process using lean 1905- Henry Ford used this production method for the first time ball bearing 1930- Kiichiro Toyoda, Taiichi Ohno use this technology for manufacturing of their cars 1945- Embargo also uses this technology to make the work more effective 1970-2005- almost all the big companies started using the concept of lean in there production system
Definition
Doing more by using less time, less inventory, fewer workers, less space Lean manufacturing is a systematic approach to remove MUDA through continuous improvement that is being adopted. Basically lean identify and eliminated the non value added activities from the process.
Reduction in cycle time On time delivery Reduction in WIP Improvement in quality Reduction of muda Reduction in rework
Q.C.D.S.M
Where Q- Improving Quality C- Cost reduction D- Delivery on time S- Providing Safety to employees M- Increasing Morale of the employees
competitive advantage. Seeks fast flexible flow. Eliminates/prevents waste (Muda). Extends the Toyota Production System (TPS).
Process
Basic steps of lean management
Specify value
Value is defined by the customers and is only applicable when it is expressed in terms of specific product i.e. A product that a customer need at specific time and at specific selling price.
Pursue perfection
Perfection is defined as achieving all the required system performance measures at the highest levels.
Here perfection means achieving all the goals of lean i.e. Q.C.D.S.M
Standardized production
This production involves setting , documentation and maintaining standard for three major areas of production Cycle time- the time within which an individual have to finish a task given Work process- layout of work area, required tools and steps WIP- work in process is the term used for inventory
Kaizen
Kaizen is a Japanese word which means change for improvement. Kaizen refers to activities that continually improve all functions, and involves all employees from the CEO to the assembly line workers
The Toyota Production System is known for kaizen, where all line personnel are expected to stop their moving production line in case of any abnormality.
Just in time
Just in time is an operating strategy that seeks in maximizing operational effectiveness by creating value in the eyes of the end customer.
The focus is not only in the departmental area or on the process but its focus is totally on the entire value stream.
Poka yoke.
Poke yoke is a Japanese term. Earlier it was know by the name of bake yoke which means foolproofing and this technique was not liked by the employees because of its connotation Then in 1961 it was know as poke yoke which means mistake proofing or error proofing. Poka yoke is a bunch of small devices like fixtures, jigs, warning signals, and many more device that helps in preventing defects.
All work shall be highly specified as to content, sequence, timing, and outcome. and there must be an unambiguous yes-or-no way to send requests and receive responses. simple and direct.
the scientific method, under the guidance of a teacher, at the lowest possible level in the organization
Service Wastes
Delay customers waiting for service. Duplication having to re-enter data, repeat
details etc. Unnecessary movement - poor ergonomics in the service encounter. Incorrect inventory out of stock. Opportunity lost to retain or win customers. Errors in the transaction, lost/damaged goods.
Benefits of Lean
Five primary types of benefits:
Cost savings Revenue increases Workforce improvements Uncovering problems
Xerox
1980s established Leadership Through Quality Initiative
which focused on improving business processes in order to improve customer satisfaction, quality, and productivity. Late 1990s and we see Six Sigma and Lean being adopted by Xeroxs manufacturing and supply chain functions.
Mid 2002 Xeroxs leadership decided to integrate its Lean and Six
Sigma programs across the entire enterprise, naming the initiative Xerox Lean Six Sigma. Xerox estimates that it achieved an initial $6 million return in 2003 based on a $14 million investment in Lean Six Sigma and expects even bigger gains in the years ahead.
Honeywell International
A diversified technology company with 2004 sales in
excess of $25 billion. Successfully integrated lean process in 1987. Honeywell competes in four major industry segments: Aerospace, Automation and Control Solutions, Specialty Materials, and Transportation Systems.
Summary
Lean manufacturing was developed by the Japanese. Lean is a philosophy that seeks to eliminate waste in all aspects of a firms production activities. Lean is principally associated with manufacturing industries but can be also equally applicable to both service and administration processes. Cornerstone of Lean is the Toyota Production System. Considers 7 Wastes (muda).
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