Lean Production System

3 Ms
MUDA = Non-Value Added
MURA = Overburden
MURI = Unevenness

Lean Production System

Muda . Mura . Muri
12 TONS
1 TON

4 ton

Capacity : 4 tons

Lean Production System

X

2 =

MURI (OVERBURDEN)

6=

MUDA (NON-VALUE ADDED)

MURA (UNEVENNESS)

Lean Production System

The most efficient way to deliver 12 tons of good to the destination is:

NO MURI (OVERBURDEN)
X

3 =

NO MUDA (NO WASTAGE)

NO MURA (NO UNEVENNESS)

7 Types of Waste
1.
2.
3.
4.
5.
6.
7.

Overproduction
Inventory
Time/Waiting
Transportation
Processing
Motion
Defects

* 7 Wastes as identified by Taiichi Ohno

7 Wastes: Overproduction
Producing more than your customer is
requesting or before they request it
1.
2.
3.
4.
5.
6.
7.

Overproduction
Inventory
Time/Waiting
Transportation
Processing
Motion
Defects

7 Wastes: Inventory

More materials or information than is

required
1.
2.
3.
4.
5.
6.
7.

Overproduction
Inventory
Time/Waiting
Transportation
Processing
Motion
Defects

7 Wastes: Time/Waiting
Waiting done by customers or by
1. Overproduction
employees
2. Inventory
3.
4.
5.
6.
7.

Time/Waiting
Transportation
Processing
Motion
Defects

7 Wastes: Transportation
Unnecessary conveyance of products,
from one location to another, or handoff
from one employee to another
1.
2.
3.
4.
5.
6.
7.

Overproduction
Inventory
Time/Waiting
Transportation
Processing
Motion
Defects

7 Wastes: Processing
Unnecessary manual work that does not
contribute value to the product
1.
2.
3.
4.
5.
6.
7.

Overproduction
Inventory
Time/Waiting
Transportation
Processing
Motion
Defects

7 Wastes: Motion
Unnecessary physical or mental motion
often associated with searching
1.
2.
3.
4.
5.
6.
7.

Overproduction
Inventory
Time/Waiting
Transportation
Processing
Motion
Defects

7 Wastes: Defects
A mistake which reaches the customer
1.
2.
3.
4.
5.
6.
7.

Overproduction
Inventory
Time/Waiting
Transportation
Processing
Motion
Defects

Lean Production House

Lean Production System
Just-in-Time
Leveled Production
Pull System
Continuous Flow
Processing

Jidoka (Automation)
Andon-Fixed Position Stop
System

Pokayoke- Fail Proofing

System

Takt Time
Flexible Work Force
3 Ms
5S

Standardized Work

Kaizen (Continuous Improvement)

Lean Production System

Just-in-Time (JIT) System
Just-in-Time means PRODUCING:
a) Only what is needed
b) in necessary quantity
c) at necessary time

Lean Production System

Main Components of JIT

Leveled Production

Pull System

Continuous Flow Processing

Takt Time

Flexible Workforce (Shojinka)

3 Ms

5S

Lean Production System

Leveled Production means producing
various model variations on the same line
to cater the customer demand

Conveyer Belt

Lean Production System

Leveled Production-Flexible Production Line

Lean Production System

Pull System (Dont Push)
Produce only when your customer
demands the product in the required
quantity.
Run the production according to this
demand

Lean Production System

Pull System or Kanban System?
Kanban is Japanese word for visual signal or
card. Toyota line-workers used a kanban (i.e.,
an actual card) to signal steps in their
manufacturing process. The systems highly
visual nature allowed teams to communicate
more easily on what work needed to be done
and when. It also standardized cues and refined
processes, which helped to reduce waste and
maximize value.

Lean Production System

Continuous Flow Production
In TPS it means arranging work inside
each process to flow smoothly from one
step to other

Lean Production System

Just-in-Case (JIC) Involves the use of buffer or safety stock

Buffer
or
Safety Stock

Process A

Process B

Buffer
or
Safety Stock

Process C

Lean Production System

Process A

Process B

Process C

Lean Production System

Process A

Process B

Process C

Lean Production System

Process A

Process B

Process C

Lean Production System

Process A

Process B

Process C

Lean Production System

Defect detected at
Process B that
actually
occurred at
Process A

Process A

Process B

Process C

Lean Production System

Smooth Flow Processing

Process A

Process B

Process C

Lean Production System

Smooth Flow Processing

Process A

Process B

Process C

Defect is detected and

countermeasures
are taken immediately

Lean Production System

Takt Time: Takt is a German word meaning meter.
It is the time to finish a given amount of work-doing a single
operation, making one component, or assembling an entire car.

Takt time =

Total daily operating time

Total production requirement

Takt time =

480
100

= 4.8 min/ vehicle

Lean Production System

Flexible Workforce (Shojinka)
Flexible workforce or shojinka means to
alter (decrease or increase) the number of
operators within a shop, to equip with
demand changes.

Lean Production System

Multi-machine Handling
Type of Part

A
Machine (Lathing)

Machine (Milling)

Machine (Drilling)

Machine (Tapping) 4

D
Unfinished Parts

Finished Products

One person handles one process, four machines

Lean Production System

Multi-process Handling
Type of Part

A
Machine (Lathing)

Machine (Milling)

Machine (Drilling)

Machine (Tapping) 4
One person handles four processes, four machines

Lean Production System

5S

Lean Production System

What is Jidoka

Automation with human intelligence

Lean Production System

Benefits of JIT
Reduction of direct and direct labor by eliminating non-value added

activities
Reduction of floor space and warehouse space per unit of output
Reduction of setup time and schedule delays as the factory becomes
a continuous production process.
Reduction is waste, rejects, and rework by detecting errors at the
source.
Reduction of lead time due to small lot sizes, so that downstream
work centers provide feedback on quality problems.
Better utilization of machines and facilities.
Better relations with suppliers.
Better integration of and communication between functions such as
marketing, purchasing, design, and production.
Quality control built into the process.