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Lean Manufacturing • Introduction and overview • Practices of lean • Principles of lean • Types of wastes in lean manufacturing • Goals and strategy of lean manufacturing • Notions in the strategic elements in lean • Steps in implementing a lean project management system. • Steps of lean transformation • Pros and cons of lean manufacturing
Lean Manufacturing
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Introduction and Overview • Lean manufacturing is a method used by
companies to reduce wastes or address waste issues in their manufacturing systems without compromising or reducing productivity.
• Wastes can be idle employees who aren't engaged.
• They can be Materials that cannot be recycled for use.
• All wastes drag productivity. Lean management comes in to eliminate these wastes while maintaining productivity.
• It is also called lean production. Lean methodology has revolutionized the business sector as a whole.
Practices of Lean
• Lean consist of a set of tools that eliminate • Waste can be created by unevenness in workloads. • Removal of waste from manufacturing has a positive effect on quality.
• Removal of wastes reduces the costs of operation of the manufacturing system
The Practice of Lean Consists of these Set of Tools:
• Kanban boards • Value stream mapping • Multi-process handling • Single-point scheduling • Production flow analysis • Error proofing • Control charts • Single-Minute Exchange
of Die. SMED.
Principles of Lean
• Flexibility • Automation • Pull processing • Waste minimization • Continuous improvement • Load leveling • Perfect first-time quality
• The above principles are shared among many methods of lean.
• The principles reduce the three main types of lean available.
• It is through these principles that lean increase productivity.
• It makes it easy to manage the work environment.
• The principles of lean thinking spearhead to organizational
Types of waste in Lean Manufacturing • Waste is a complicated
concept. • Waste is defined in three
ways which are: - Unevenness – commonly
knowns as Mura. - Overburden – also known
as Muri - Process waste – known as
Muda.
Types of waste in Lean Manufacturing
• Unevenness is a waste that results from demand fluctuations. The fluctuations can be generated from customer requests.
• Overburden is a waste that originates from strife, doing a lot of work in a short period.
• Process wastes are wastes that come as a result of by- products of the manufacturing process. Wastes here are necessary though they can be engaged in activities that add value.
Summaries of Process Wastes are put in Acronym DOWNTIME
• Defects • Overproduction • Waiting • Non-utilized talent • Transportation • Inventory • Motion • Extra-processing
Goals and Strategies of Lean Manufacturing
• The common goals include: - Improving quality - Eliminating quality - Reduction of time - Reduction of total costs
Goals of Lean Manufacturing Cont.
• Quality makes manufacturing companies competitive. Companies also strive to meet the customer's needs. • Wastes increase the cost of production, thereby resulting in
losses. • Wastage of time is possibly a wastage of money. Time and
money are at one side into consideration. • Companies save a lot of money when they aren’t wasting
time materials for production and personnel activities.
Notions in the Strategic Elements in Lean
• Toolbox lean is lean as a set of tools
• The lean mind is lean as a philosophy
• Acquiring lean means perceiving lean as a continuous change process
• To become is to have lean as a goal or a fixed state.
Steps in Implementing a Lean Project Management System
• There are three steps in implementation:
- Designing a simple manufacturing system
- Looking for ways of improvement
- Kaizen principle of continuous improvement.
Steps of Lean Transformation
• Lean transformation has five processes: - Value identification - Mapping the value stream - Flow creation - Pull establishment - Perfection seeking
Steps of Lean Manufacturing Cont.
• Value specification deals with the definition of value from the final consumer's perception of how the final product is designed to meet its needs.
• Mapping is all about identifying the value stream. • The third step involves making the remaining steps in the value
stream to flow by eliminating functional barriers and developing a product-focused organization.
• The customer then needs to pull products as they need them. • The last step is all about perfection, which means a reduction of time,
effort, cost, and mistakes.
Advantages of a Lean Manufacturing System
• Lean manufacturing eliminates wastes
• It increases profits • It ensures employee satisfaction • There is sustainability in the
company • Companies experience
improved lead times • There is increased product
quality.
Advantages of a Lean Manufacturing System Cont.
• Eliminating wastes is the main objective of lean manufacturing. • Lean manufacturing increase company profits by reducing the wastes
which are associated with loss.
• Workers in lean manufacturing know their work and what is not meant for them.
• Companies acquire sustainability due to the fewer wastes and the increased profits they get in the process.
• Lead time is when an order is placed by the customer and the time the product or materials are delivered. A better environment creates a reasonable lead time.
• The quality of products increases due to the fewer wastes available in the manufacturing system.
Disadvantages of Lean Manufacturing
• The high cost of implementation • Supply problems • Problems of Customer
dissatisfaction • Employees may not accept
the lean implementation
Disadvantages of Lean Manufacturing Cont.
• Implementing lean manufacturing into the systems may be so hectic when it requires many companies' funds to adopt. • Lean manufacturing needs reliable suppliers, without which
it may fail. • Customers may not be satisfied with fixed products initially;
there may be underproduction due to the reduction of excess in the market. • Employees may find it challenging to adapt to the new lean
system, thereby creating process delays that affect the whole course of manufacturing.
Conclusion • Lean manufacturing is a
transformation in the manufacturing sector that businesses once embraced; there is a realization of profits.
• Every business can practice lean; it is not tied to the manufacturing sectors alone.
• Lean manufacturing has a lot of advantages than its disadvantages; therefore, it is recommendable.
• Companies without lean systems lose a lot from wastes that can otherwise be reduced by lean.
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