Lean Manufacturing (Concepts, Tools and Quality Management)
- 1. Lean Manufacturing Concepts, Tools and Quality Management
- 2. 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 ;
- 3. What is Lean? Persistent process in elimination of waste – MUDA – describes any activity that’s done, but add no real value to the product or service.
- 4. What is Lean? Respect for people High Quality and Stable Processes
- 5. 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;
- 6. 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.
- 7. Short History 1913: Henry Ford 1938 JIT Born (Start of mass manufacturing with the moving line)
- 8. Short History □ 1950: Eiji Toyoda brings the ideas of continuous moving line in Japan.
- 9. Short History 1960: Toyota production System, main principles of lean manufacturing 1991: Lean Management
- 10. 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
- 11. Lean Tools Assessment and planning- fundamentals and understanding where we are today and creating and design for tomorrow. Plan, Do, Check, Act
- 12. Lean Tools 5 “S” Visual control Standardize work Total productive maintenance
- 13. Select the key Reduce cost of production Increase customer satisfaction Improve quality Select the key Map Process Eliminate Waste Make Process Flow Establish Customer Poll
- 14. What Is Waste? Waste of overproduction (largest waste) Waste of time on hand (waiting) Waste of transportation Waste of processing itself Waste of stock at hand Waste of movement Waste of making defective products
- 15. Lean Thinking • Value - what customersarewilling to pay for; •Value Stream – the steps aredeliveredvalue; •Flow –organizing ValueStreamto be continuous; •Polls – respondingto downstreamcustomerdemand; •Perfection – relentlesscontinuousimprovement (culture); Key Principals of Lean Thinking Lean Thinking, Womack and Jones,1996
- 16. 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.”
- 17. Production System Two pillars: Jidoka Just-in-time
- 18. What is Jidoka? “Jidoka” means autonomous. The responsibility of each associate to deliver Quality to the customers. - Intense Motivation Training; - Explained Information;
- 19. Just-in-time Aims of zero inventory; Parts are not kept in warehouse; Parts arrive when needed;
- 20. Quality system Quality means compliance with specifications- no less, no more; No need for inspections!
- 21. Quality Assurance When we focused on this we will consistently deliver what the customer expects; Trust raises everyone’s commitment
- 22. Thank you!