paper2
AboRedha
projectpowerpoint2.pptxLean 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
Student’s Name
Institution
Course
Instructor’s Name
Date
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 structure.
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.
