LEAN MANUFACTUING-CONCEPT,

LIMITATION, APPLICATIONS: AN
OVERVIEW
Submitted By
Ms. PUNAM NIVRUTTI PATIL
DPGD/OC13/1243
SPECIALIZATION: OPERATIONS

WELINGKAR INSTITUTE OF MANAGEMENT DEVELOPMENT & RESEACH

AUGUST 2015

INTRODUCTION

Lean manufacturing- A way to eliminate waste & improve efficiency in

manufacturing environment.
Lean was generated from just in time(JIT) Philosophy of continuous &
forced problem solving.
Lean is the fundamental way that many of the worlds best companies do
business.
It is the production of goods using less everything compared to traditional
mass production.

FORMS OF WASTE
Muda- Any form of
waste in process
Muri- Unreasonable
burden on people or
machines
Mura- Waste created
through unevenness

GOALS
Improve Quality

Reduce total costs

Reduce Time
Zero accidents
Zero inventory

LEAN MANUFACTURING PROCESS

Identify waste

Analyze the
waste & find
the root cause

Solve the root

cause & repeat
the cycle

TOOLS

5S
Andon
Bottleneck Analysis
Continuous flow
Gemba
Heijunka
Hoshin kanri
Jidoka
Just In Time
kaizen

Kanban
Key performance indicator
Overall equipment effectiveness
PDCA
Poka Yoke
Root cause analysis
SMED
Takt time
Total productive maintenance
Value stream mapping
Visual factory

Some of important tools

5S
Clearing (Seiri)
2. Organizing (Seiton)

3. Cleaning ( Seiso)
4. Standardization (Seiketsu)

5. Discipline & Training (Shitsuke)

Just In Time
The ideal just in time facility would
carry zero finished goods and build
them only when they are ordered

kaizen
Kaizen simply means "change for
better
The Toyota Production System is
known for kaizen

KANBAN
The basic concept of a kanban is a hand
sized card that moves with the product or
material.
There are two basic classifications of
kanbans; generic and brand.

Total Productive
Maintenance

TPM (Total Productive Maintenance) is a

Within the two classifications there are holistic approach to equipment
two main types of kanbans; production maintenance that strives to achieve
kanbans and move kanbans
perfect production:
No Breakdowns
No Small Stops or Slow Running
No Defects
In addition it values a safe working
environment:

No Accidents

KEY IMPLICATIONS OF LEAN MANUFACURING

Traditional Batch Manufacturing

Lean Manufacturing

Orientation

Supply driven

Customer driven

Planning

Orders as pushed through factory

Orders are pulled through factory
based on production plan / forecast based on customer / downstream
demand

Inventory

Buffer of work in progress between

each production stage

Little or no wok in progress

between each production stage

Handoff of work in process

Material after each stage

accumulate into work in progress
stage areas before being retrieved
by next production stage

Material handed of directly from

one production stage to next

Production cycle time

Longer than actual time

Shorter

LIMITATIONS

Supply Problems
High cost of implementation
Lack of acceptance by employees
Customer dissatisfaction problems
New inefficiencies
Problems in Just In Time (JIT)
Worker frustration
Over focus on waste
Over focus on present
Lack of standard methodology

APPLICATIONS
In process industries
In financial service sector
In emergency department
In construction industries
In pharmaceutical industries
In public

Toyota Production
System
TPS has three desired outcomes:
To provide the customer with the
highest quality vehicles, at
lowest possible cost, in a timely
manner with the shortest
possible lead times.
To provide members with work
satisfaction, job security and fair
treatment.
It gives the company flexibility to
respond to the market, achieve
profit through cost reduction
activities and long-term
prosperity.

CONCLUSION
Lean manufacturing is:
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.