Académique Documents
Professionnel Documents
Culture Documents
Lean Manufacturing
Colin Haley
Mike Tulk
Jon Farrell
Lean Manufacturing
Principles
and practices
Specific manufacturing examples (former
Terra Nova Shoes)
Seven Wastes
Most
Wastes
Wastes
Seven Wastes
Overproduction
Down Time
Transportation
Inappropriate Processing
Unnecessary Inventory
Unnecessary Motions
Defects
Overproduction
Producing
Creates
Increases
Difficulty
storage cost.
of finding defects.
Down Time
Idle
products or employees.
Concentrate
Transportation
Inefficient
No
factory layout.
value added.
Opportunity
for damage.
Inappropriate Processing
Cheap
Less
Several
Unnecessary Inventory
Unnecessary Motions
Keep ergonomics in
mind
Misplaced tools.
Searching for materials.
Defects
Kaizen Strategies/Goals
Kaizen Implementation
Easier
Safer
Less unpleasant
More efficient
Improvements
Small
Rapid
Utilize minimal resources
Discover problem
Brainstorm solutions
Apply rapid implementation
Monitor for success
5-S Implementation
The 5-Ss
Benefits of 5-S
Increased morale
Safety
Non-Value Added activity decreased
Efficiency and organization
Increased quality
Faster Lead Time
Increased creativity, and willingness to contribute
among employees.
5-S Examples
5-S Examples
Before
After
Just-In-Time (JIT)
Technique
JIT: Benefits
JIT: Strategies
Preventative Maintenance
Jidoka
Definition: It is the ability for machines to be selfdependent and error proof without any human
interaction.
3 Elements:
Separate human from machine work
Machines detect/prevent abnormalities
Stop the Line authority in operation
Pokayoke
Simple
Pokayoke (contd)
Pokayoke
Kanban
Card
Kanban (contd)
There
Production Kanban
Conveyance Kanban
Production
Kanban (contd)
Environments
Kanban (contd)
Basic Rules of Kanban
Cellular Manufacturing
Work
Higher throughput
Improved coordination
Strong sense of teamwork
Improved quality and productivity
Simplicity of cellular manufacturing
13
12 2
10 1
5 8
General Problems
Large
Lean Approach
It
Benefits of SMED
Increased flexibility
Elimination of waiting
Operators preference
Stockless production
system
External Setup: One that may be completed
while machine is in operation
Internal Setup: One that requires the shut
down of the machine for completion
Simple Suggestions
Analysis
SMED Examples
Split
thread bolts
Handles
Toggle clamps
U-shaped washers
Example Tools
u-shaped washers
SMED Examples
SMED Examples