Welcome to a Presentation on Lean Manufacturing

By Saurabh Gautam 29274 B.Tech 3rd Year Mechanical Engineering

Introduction
Definition
A production practice which aims at detection and removal of wastes from manufacturing and completing the job at minimum cost.

Figure 1

Historical Background
Originated by Toyota in 1950s
Developed jointly by Taiichi Ohno and Shigeo Shingo Based on the philosophy of Preserving value with

less work Initially known by the name Just-in-Time (JIT) production Later came to be known as Toyota Production System Lean Manufacturing is the latest name of JIT

Just-in-Time Production

Overview of Toyota Production System

The 8 wastes

Figure 2

Mechanism of Lean Manufacturing

Lean Building Blocks
Pull System

Figure 3

Kanban

Figure 4

Continued

Work Cells

Figure 5

Concurrent Engineering

Figure 6

Continued
5S or Workplace Organisation

Figure 7

Continued
Batch Size Reduction
Quick Changeover Total Productive Maintenance Total Quality Management Visual Controls

The TPS House

Figure 8

Analysis of Lean Manufacturing through some Industrial Case Studies

Case Study 1: Internationalization of Honda Motor Co.
Honda is the famous Japanese multinational

company It was established in 1948 Manufactures automobiles, motorcycles and lawn mowers Presently has 119 manufacturing facilities in 33 countries

Figure 9

Continued
Honda began its internationalization in 1959 by

founding Honda Motor Co. Inc. in USA. It took an FDI and founded Honda of America Manufacturing which started production in 1981. In mid 1980s, Honda took a giant leap to become a multinational brand by dividing the world into 5 strategic regions: North America, South America, Africa, Asia and Japan. Each region was responsible for its R & D, production, profits etc.

Continued
Honda changed its manufacturing philosophy to

Lean in the mid 1990s to make its production more flexible. It was able to build different, cheap cars for different markets and yet achieved economies of scale. Honda showed how productivity can be increased without increasing the input cost by implementing the Lean Manufacturing System (LMS). Just a slight change in the production methodology has made Honda one of the greatest competitors in the car-industry.

Case Study 2: Lean manufacturing and EMS in the Shipbuilding Sector

Environmental Management System(EMS) has

become an integral part of the manufacturing sector. Lean and EMS are different yet complimentary to each other. Shipbuilding companies divide wastes in two categoriesType 1(unnecessary) and Type 2(necessary). Through EMS, these companies try to reduce type-2 wastes. Implementation of Lean with EMS

Benefits of Lean Manufacturing

Lead Time reduced by 90%
Productivity increased by 50% Work-in-Process Inventory reduced by 80% Space utilization reduced by 75% Quality improved by 80% Reduction in Order processing errors Streamlining of processes Reduced lead-time allows for various strategic

improvements in the organisation.

Conclusion
Lean organizations are more responsive to

market trends. They deliver products and services faster in an economical and inexpensive manner. It not only reduces work-in-process inventory but also lot sizes which increases inventory turns. It reduces material handling distances and rapid feedback from downstream work-centres. Results in continually declining costs, zero defects, low inventories and endless product variety.

Thank You