A Training on 3 M’s in Lean

Management

By Pramod A

Dec 2015

Lean Management

• Lean Management of “Lean” is the optimal way of managing a process through the removal of wastes and Implementing a flow.

• More value with Less work• Lean Manufacturing is mostly derived from Toyota

Production System (TPS) and identified as “Lean” only after 1990.

• Ultimate goal is the removal of all wastes in the Process.

Dec 2015

Toyota Production System

• Make what the customer needs, when it is needed, and in right amount.

• Minimize Inventories.• Full utilization of all Potentials.• Building Quality in the process and Prevent errors from

happening.• Reduction of through put time.

Dec 2015

Lean Production - TPS

The Main goals of TPS are to eliminate 3 M’s which are,• Muri (Overburden or stress in the system)• Mura (Inconsistency, Un-evenness)• Muda (Waste)

Ultimate Goal is to design a process that runs smoothly, without stress and eliminates wastes.

Dec 2015

3 M’s

Dec 2015

Muda

What is Muda?...• Work that does not add any value to

the product or the activities which the customer is not paying for.

Dec 2015

Economic Value of Muda

• Every Business activities absorb resources and each resource has a cost.

• Every waste has a cost and that is a direct loss to the company.

• Economic value of the waste in a process industry are in the range of 10% - 35% of annual turnover

Dec 2015

Types of Muda

7 Types of Muda

Dec 2015

Muda of Motion

Movement that does not add value.• Searching of Files• Gathering Information• Looking through manuals and

catalogs• Handling Paperwork

“The Movement of People Within the Workspace”

Dec 2015

Muda of Waiting

Waiting constricts smooth flow. it interrupts the work rhythm• Job waiting to be loaded into a machine• Products waiting for inspection• Waiting for raw materials and parts• Customer Response

Dec 2015

Muda of Transport

• Transportation adds time to the process without increasing value, and creates an opportunity for damage to occur.

• Poor plant layout leads to transportation wastes, and waste can be removed by achieving the shortest distance in a straight line.

"The Unnecessary Movement of Materials"

Some results of unnecessary transportation:• cost• damage• time lost• spillage• wasted investment in logistic equipment

Dec 2015

Muda of Over Production

"Producing More than Required Amount"

Overproduction arises from fear or concerns of stock outs or a misunderstanding of demand• A process that continues

when its output is not required causes excess inventory. Over-production is generally regarded as the worst type of waste, it leads to all the other wastes.

• “Produce the right amount at the right time.”

Dec 2015

Muda of Inventory

Get rid of 'just in case inventory'; it ties up cash and requires additional storage facilities. Excess storage can cause stock damage, and materials can degrade in store.• Old stock items that aren’t currently

used in production.• Needs space.

• Costs money.

• Requires finding.

• Needs intermediate storage and people to move them.

• can hide problems

"Stock that is Not Required for Customer Orders"

Dec 2015

Muda of Over Processing

"Doing More than needed to Meet the Customer Requirement"

Efforts that create no value from Customers view point• Completing two or three

inspections,• Measuring components more than

once• Use of Outdated standard forms

Dec 2015

Muda of Defects

Producing parts, products, or services that are defective results in scrap and rework; it also wastes supplies and leads to customer dissatisfaction.• Making items to the wrong specification

The production of defects or scrap results in:• additional materials usage• additional transportation• additional control• space for quarantined stores• space for repairing

Reduce defects and scrap through:• Search for and elimination of causes • Build in Quality (QA process sheets)

"Doing Nice or Do It Twice"

Dec 2015

Mura

Eliminating unevenness or irregularities in any operation or process is one of the main principles of the Just-In-Time system, the main pillar of the Toyota Production System.• Mura is the waste of unevenness or

inconsistency.

Dec 2015

Muri

Muri is the Over Burden on equipment, Facilities & People caused by Muda and Muda.• Pushing a machine or person beyond

its limits.

Dec 2015

Muri

Results • Overburdening peoples results in

safety and quality problems.• Overburdening machines causes

breakdown and defects.

Dec 2015

Lean Solutions

• First you must see it – MAKE IT VISIBLE!

Dec 2015

Lean Solutions - Value Stream Mapping

You can See and Identify Waste as you connect your processes from start to finish

Dec 2015

Lean Solutions

• Problem Solve

Plan Do

CheckAct

Dec 2015

Lean Solutions

• Keep watching