8 lean concepts
TRANSCRIPT
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Lean Production
Lean manufacturing orlean production, which is often known
simply as "Lean", is the optimal way of producing goods
through the removal of waste and implementing flow, as oppose
to batch and queue.
A combination of multiple tool sets
JIT production
Safe workplace (5Ss)
Pursuit of perfection
Visual management
Empowered teams
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Lean
Remove waste, rework, inventory to reduce flow time
Flow focused
Remove bottlenecks Material velocity
Immediate results
(1-2 weeks)
Low complexity with known solutions
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Lean Concepts JIT
Kanban: Signboard signal to authorize production
Andon: Lantern board that signals quality issue
Kaizen: Continuing improvement involving everyone
5 Ss
Poka Yoke: mechanism to stop defects or make
errors obvious
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Just-in-time means the right part at the right
place in the right amount at the right time.
shortens cycle times,
decreases the amount of inventory that a company carries,
leads to low work-in-process (WIP), and
creates a flexible atmosphere for the type or amount of
product that a company would like to run and most of all
streamlines work flow through a manufacturing facility.
JUST IN TIME
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KANBAN
means "visual," and ban, means "card" or "board")
Kanban is a signaling system to trigger action.
Kanban is not an inventory control system. Rather, it is a
scheduling system that tells you what to produce, when to produce
it, and how much to produce.
Historically uses cards to signal the need for an item.
Other devices such as plastic markers (kanban squares) or balls
(often golf balls) or an empty part-transport trolley or floor location
can also be used to trigger the movement, production, or supply of
a unit in a factory.
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KANBAN CARD
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ANDON
Refers to a system to notify management, maintenance, and
other workers of a quality or process problem. E.g., signal,
siren, board
It gives the worker the ability to stop production when a
defect is found, and immediately call for assistance.
Common reasons for manual activation of the Andon are
part shortage, defect created or found,
tool malfunction, or
the existence of a safety problem.
Work is stopped until a solution has been found.
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Kaizen
Value-added and non value added work
activities
Muda- refers to 7 classes of waste-
over production, delay, transportation,
processing, inventory, wasted motion &defective parts
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Kaizen
Principles of material handling & the use of time-
piece flow
Documentation of standard operating procedures
The 5-s for workplace organization proper
arrangement (seiko), orderliness (seiton),
personal cleanliness (seiketso), cleanup (seiso) &
discipline (shitsuke) Visual management by means of visual displays
that everyone in the plant can use for better
communications
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Kaizen sheet is a useful way of depicting the
information relating to the implementation of a
kaizen suggested by an individual or a group ofworkers.
In this example:
two men engaged on three machines for removing
oil from center bolt cut length with saw dust
Conducted a WHY flowchart for every cause
Root cause identified as excessive flow of oil on the
machine so that the job being processed on themachine used to get wet with oil
Kaizen idea: reduce the flow of oil
Use a sponge wet with oil touching the rollers
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BEFORE KAIZEN
Oil consumption/day 5 liters
Price/liter Rs 16.66
Cost of oil/day Rs 83.3 Cost of oil/month (26 days) Rs 2165
Cost of oil/year Rs 25989
Salary of 2 persons/year Rs 48000
Saw Dust consumption/day 23.3 kgs
Saw dust cost/bag Rs 21
Monthly expenses of saw dust Rs 546
Yearly saw dust expenses Rs 6552
Monthly electricity expenses Rs 65
Yearly electricity expenses Rs 780
TOTAL: Rs 81322
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AFTER KAIZEN
Yearly Expenses of oil
(0.7litre/day X 26 X 12) Rs 3465
Total saving/Year
(81322 3465) Rs 77857
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OtherKaizen Tools: 5 SsStep Name Action Catch Phrase
1Sort
(Seiri)
Removeunnecessary
itemsfromthe workplace Whenindoubt,throw it
out
2S
traighten,S
etin
Order
(Seiton)
Locateeverythingatthe
pointofuse Aplaceforeverything,
andeverythinginits
place
3Sweep, Shine
(Seiso)
Cleanandeliminatethe
sourcesoffilthThebestcleaningisto
notneedcleaning
4Standardize
(Seiketsu)
Makeroutineandstandardforwhatgoodlookslike Seeandrecognize what
needstobedone
5Self-discipline, Sustain
(Shitsuke)
Sustainbymaking 5S
secondnature Thelessself-discipline
youneed,
the
better
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Mudas 7 Wastes
The
7
Wastes
Definition
Examples Causes Counter measures
Over-
|produ
ction
Producing
more than
the
customerneeds right
now
Producing
product to
stock based on
sales forecastsProducing
more to avoid
set-ups
Batch processresulting in
extra output
Forecasting
Long set-
ups
Just incase for
breakdowns
Pull system
scheduling
Heijunka
level loadingSet-up
reduction
TPM
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Trans-
portation
Movement of
product thatdoes not add
value
Moving parts in
and out of storageMoving material
from one
workstation to
another
Batch
productionPush
production
Storage
Functional
layout
Flow lines
Pull systemValue Stream
organizations
Kanban
The 7
Wastes
Definition Examples Causes Counter
measures
Motion Movement of
people that
does not add
value
Searching for
parts, tools, prints,
etc.
Sorting through
materials
Reaching for tools
Lifting boxes of
parts
Workplace
disorganization
Missing items
Poor
workstation
design
Unsafe work
area
5S, Point of
Use Storage
Water Spider
One-piece flow
Workstation
design
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Waiting Idle time
createdwhen
material,
information,
people, or
equipment
is not ready
Waiting for parts
Waiting for printsWaiting for
inspection
Waiting for
machines
Waiting for
informationWaiting for
machine repair
Push production
Work imbalanceCentralized
inspection
Order entry
delays
Lack of priority
Lack ofcommunication
Downstream
pullTake time
production
In-process
gauging
Office Kaizen
TPM
Processi
ng
Effort that
adds no
value fromthe
customers
viewpoint
Multiple cleaning
of parts
PaperworkOver-tight
tolerances
Awkward tool or
part design
Delay between
processing
Push systemCustomer voice
not understood
Designs thrown
over the wall
Flow lines
One-piece pull
Office KaizenLean Design
The 7
Wastes
Definition Examples Causes Counter
measures
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Inventor
y
More
materials,
parts, or
products on
hand than
the
customerneeds right
now
Raw materials
Work in process
Finished goods
Consumable
supplies
Purchased
components
Supplier lead-
times
Lack of flow,
Long set-ups
Long lead-times
Paperwork in
processLack of ordering
procedure
External
kanban
Supplier
development
One-piece flow
lines
Set-upreduction
Internal
kanban
Defects Work that
containserrors,
rework,
mistakes or
lacks
something
necessary
Scrap, Rework
DefectsCorrection
Field failure
Variation
Missing parts
Process failure
Mis-loaded partBatch process
Inspect-in
quality
Incapable
machines
Pokayoke
One-piece pullBuilt-in quality
3P
Jidoka
The 7
Wastes
Definition Examples Causes Counter
measures
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KAIZEN at TAJ HOTELS
ENERGY CONSERVATION AT TAJ BENGAL
Before: Electrical energy was being wasted due to misuse/under
use of electrically operated kitchen equipment such as hot ranges,
ovens and salamanders in various kitchens
After: All the under used electrically operated kitchenequipment have been disconnected and removed
Before: Fresh air and exhaust fans were running beyond the
operating hours in various kitchens
After: Timers have been provided for fresh air and exhaust fans
for various kitchens
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Before: Unwanted lights in lobby corridors were on during
the night
After: The 300 W halogen lights have been replaced with 70
W metal halide lamps. Timers have been provided and
cabling modified for the alternative hundi lights of lobby
corridors.
GAINS: Annual savings of Rs 19.62 lakh and in terms of
savings in electricity, there is a total saving of 4,01,317 kwh
annually.
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POKA-YOKE
A Japanese term that means "fail-safing" or
"mistake-proofing" avoiding (yokeru)
inadvertent errors (poka) is a behavior-shaping constraint, or a method of preventing
errors by putting limits on how an operation
can be performed in order to force the correctcompletion of the operation.
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ExamplesofPoka-Yoke
The inability to remove a car key from the ignition switch
of an automobile if the automatic transmission is not first
put in the "Park" position, so that the driver cannot leave
the car in an unsafe parking condition where the wheels
are not locked against movement.
In the IT world another example can be found in a
normal 3.5" floppy disk: the top-right corner is shaped in
a certain way so that the disk cannot be inserted upside-
down.
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Fueling area of car has threemistake-proofing devices:
filling pipe insert keeps larger,
leaded-fuel nozzle from being
inserted
gas cap tether does not allow the
motorist to drive off without the cap
gas cap is fitted with ratchet to signal
proper tightness and prevent over-
tightening.
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Even bathroom sinks
have a mistake-proofingdevice. It is the little
hole near the top of the
sink that helps prevent
overflows.