LEAN PRODUCTION

PRESENTED BY, NITHIN P S6 TDE ROLL NO:30

WHAT IS LEAN PRODUCTION?

It

is a team-based approach of manufacturing focused on identifying and eliminating waste through continuous improvement

Basic Elements of Lean Manufacturing

Pull

system Lead time reduction Continuous improvements

Applications of Lean Production

Lean

techniques are also applicable in service-oriented industry and service environment. The techniques for analyzing systems, identifying and reducing waste, and focusing on the customer are applicable in any system, and in any industry.

LEAN BUILDING BLOCKS

AUTONOMATION
to

prevent mass-production of defective work in machines or product lines.

LOAD LEVELING
It

is a production scheduling / load leveling tool, essentially to distribute kanban cards in an efficient manner.

TPM
goal

of TPM is to minimize downtime due to maintenance, and maximize machine uptime.

POKA YOKE
system

to create devices that can discover defectives without the workers

5S
This

tool is a systematic method for organizing and standardizing the work place
SORT STRAIGHTEN SWEEP STANDARDISE SELF DISCIPLINE

The 7 Wastes To Be Eliminated

Overproduction - producing over customer requirements, producing unnecessary materials Waiting- time delays, idle time Transportation - multiple handling, delay in materials handling, unnecessary handling Inventory - holding or purchasing unnecessary raw materials, work in process, and finished goods Motion - actions of people or equipment that do not add value to the product Over-processing - unnecessary steps or work elements Defective units - production of a part that requires rework.

Characteristics
Integrated single piece continuous workflow Just-in-time processing: a part moves to a production operation, is processed immediately, and moves immediately to the next operation Production is based on orders rather than forecasts.

KEY FEATURES

Employee Involvement And Empowerment

- organizing workers by forming teams and giving them training and responsibility to do many specialized tasks, for housekeeping, quality inspection, minor equipment repair and rework; allowing also them time to meet to discuss problems and find ways to improve the process

Continuous Equipment Maintenance

- as pull production reduces inventories, equipment breakdowns must also be reduced; thus empowered operators are assigned primary responsibility for basic maintenance since they are in the best position do detect signs of malfunction

Multi-Skilled Workforce
-

In order to have smoothed production, it is necessary that the worker be skilled in a number of functions

SHORT SET UP TIME

Through constant efforts by use of quality circles, set up times have been reduced

BENEFITS
Lead

90% Productivity increased by 50% Work-In-Process Inventory reduced by 80% Quality improved by 80% Space Utilization reduced by 75%

Time (Cycle Time) reduced by

CONCLUSION
In

the era of globalization, all the organizations try to improve productivity and quality using all the industrial engineering tools. Lean manufacturing is a dominant tool which is proven globally as one of the best tool available to improve overall operating efficiency.

THANKYOU