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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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