Lean Manufacturing

Concepts and Tools and

Quality Management

By Hristina Koycheva

What is Lean?

Lean is an Operational Excellence

Strategy that enable you to change
for the better- in fact the Japanese often use
Kaizen which use by lean practitioners to describe
incremental improvements ;

What is Lean?

Persistent process in elimination of

waste MUDA describes any activity thats

done, but add no real value to the product or service.

What is Lean?

Respect for
people

High Quality and

Stable Processes

Where?

At all level there is a strong desire to

be better;
A culture of lean is visibly prioritised
and practice from the top to the
bottom of the workforce;
The key is understanding the
customer and delivering his
requirements;

How?

Improves business performance using simple

practical tools and techniques to enhance
quality, cost, delivery and people contribution;
Exposes the wastes in the system;
People need to change their long standing work
practices and ideas;
Senior management need to drive lean
principles forward with total commitment to its
success;
Not a bolt on technique, more a way of life
leading to a total change in culture.

Short History

1913: Henry Ford

(Start of mass
manufacturing with
the
moving line)

1938 JIT Born

Short History

1950: Eiji Toyoda brings the ideas of

continuous moving
line in Japan

Short History

1960: Toyota
production System,
main principles of
lean manufacturing

1991: Lean
Management

Main Principals

Identify the customer

Map the flow
Make a product or service flow
Create polls based on customer
demands
Continually find ways to improve

Lean Tools

Assessment and
planning-

fundamentals and
understanding where we are
today and creating and
design for tomorrow.

Plan, Do, Check,

Act

Lean Tools

5 S

Visual control

Standardize work

Total productive
maintenance

Select the key

Select the
key

Reduce cost of
production

Increase customer
satisfaction

Improve quality

Map Process

Establish
Customer
Poll

Eliminate
Waste

Make Process
Flow

What Is Waste?

Waste of
waste)
Waste of
Waste of
Waste of
Waste of
Waste of
Waste of

overproduction (largest
time on hand (waiting)
transportation
processing itself
stock at hand
movement
making defective products

Lean Thinking

Key Principals of Lean Thinking

Value

Value Stream

Flow organizing Value

Polls responding to downstream customer demand;

Perfection relentless continuous improvement

- what customers are willing to pay for;

the steps are delivered value;
Stream to be continuous;

(culture);

Lean Thinking, Womack and Jones,1996

Conclusion
Lean 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.

Production System
Two pillars:

Jidoka

Just-in-time

What is Jidoka?

Jidoka means
autonomous. The
responsibility of
each associate to
deliver Quality to
the customers.
- Intense Motivation
Training;
- Explained Information;

Just-in-time

Aims of zero
inventory;

Parts are not kept

in warehouse;

Parts arrive when

needed;

Quality system

Quality means
compliance with
specifications- no
less, no more;
No need for
inspections!

Quality Assurance

When we focused
on this we will
consistently deliver
what the customer
expects;

Trust raises
everyones
commitment

Thank you!