Lean Manufacturing

LEAN
MANUFACTURING
DR MEENAKSHI SHARMA
LEAN MANUFACTURING
MEANING OF LEAN
MANUFACTURING
 Lean manufacturing is a methodology
that focuses on minimizing waste
within manufacturing systems while
simultaneously maximizing
productivity.
 The benefits of lean include reduced

lead times, reduced operating costs
and improved product quality.

WHY LEAN
KEY TO PROFITABILITY
FIVE PRINCIPLES OF LEAN
MANUFACTURING
Value
Value
Perfection
Stream
Pull Flow
CUSTOMER VALUE
 Value is what the customer is willing to pay for
 It is paramount to discover the actual or latent needs

of the customer.
 There are many techniques such as interviews,
surveys, demographic information, and web analytics
that can help you discover what customers find
valuable.
 By using these qualitative and quantitative
techniques you can uncover what customers want,
how they want the product or service to be delivered,
and the price that they afford.
VALUE STREAM
 In this step, the goal is to use the customer’s
value as a reference point and identify all the
activities that contribute to these values.
 Activities that do not add value to the end
customer are considered waste.
 The waste can be broken into two categories:
 non-valued added but necessary and
 non-value & unnecessary.
 waste should be eliminated.
 By reducing and eliminating unnecessary processes or
steps, you can ensure that customers are getting
exactly what they want while at the same time
reducing the cost of producing that product or
service.
FLOW
 After
removing the wastes from the value
stream, the following action is to ensure
that the flow of the remaining steps run
smoothly without interruptions or delays.
 Some strategies for ensuring that value-
adding activities flow smoothly include:
 breaking down steps,
 creating cross-functional departments, and
 training employees to be multi-skilled.
PULL
The goal of a pull-based system is to limit
inventory and work in process (WIP) items while
ensuring that the requisite materials and
information are available for a smooth flow of
work.
 In other words, a pull-based system allows for
Just-in-time delivery and manufacturing where
products are created at the time that they are
needed and in just the quantities needed.
 Pull-based systems are always created from the
needs of the end customers.
PERFECTION
 Wastesare prevented through the
achievement of the first four steps:
 1) identifying value,
 2) mapping value stream,
 3) creating flow, and
 4) adopting a pull system.
 However, the fifth step of pursuing perfection is
the most important among them all. It makes
Lean thinking and continuous process
improvement a part of the organizational culture.
LEAN COST MODEL
LEAN METHOD MODEL
 Traditional Method  Lean Method
 Increase Workforce  Eliminate waste
 Increase Working  Focus on efficient
Hours man power
 Add Machine  Provide sound
 Add more tools environment
 Focus on efficient
machines and tools
TOOLS OF LEAN MANUFACTURING
5 S 7 QC TOOLS
 PDCA Cycle  KAIZEN
 POKAYOKAE  JIT
3 M 5 W 2 H
 KANBAN  QCC
 PULL  TPM
 LINE BALANCING  OEE
 ANDON
BENEFITS OF LEAN
MANUFACTURING
Improve
Efficiency
Increase Reduce
Productivity Cost
BENEFITS OF LEAN
MANUFACTURING
 Improves efficiency,
 Reduces waste, and
 Increases productivity.
ADVANTAGES OF LEAN
MANUFACTRING
 Quality performance
 Reduce Process Breakdowns.
 Lower levels of Inventory.
 Less Space Required.
 Higher efficiencies, more output per man hour.
 Improved delivery performance.
 Faster Development.
 Greater Customer Satisfaction.
 Improved employee morale and involvement.
 Improved Supplier Relations.
 Higher Profits
 Increased Business
DISADVANTAGES OF LEAN
MANUFACTURING
 The Problem of Inventory
 In lean management implementation, low amounts of stock are kept on hand to
decrease carrying costs.
This causes companies to depend on suppliers and hope they are able to make
the adjustment to deliver goods quickly and efficiently.
 Difficult to Change Over

 Employees may not always be welcoming to lean management practices.
 The implementation of this style will take a lot of patience and a complete
overhaul to work processes.
Therefore, leaders have to be transparent about all changes that will happen in
the company.
CONTINUE…….
 High Implementation Cost
Most of the time, when lean
management is implemented in a company
that has never before used it, it is likely that
all systems and production processes will
have to end in their current state.
This event can bring high costs for

companies who are not prepared for the
increased expenses of bringing in new
equipment and training programs.
CONCLUSION
 Implementing Lean management in an
organization is a concept that is designed to
support the concept of continuous improvement
in a manufacturing and support organization.
 Using this approach will systematically seek to
achieve small and incremental changes in
processes in order to improve efficiency and
quality.
 Lean principles will continue to be used to
reduce waste and improve processes.

Lean Manufacturing

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LEAN

 The benefits of lean include reduced

 It is paramount to discover the actual or latent needs

 Reduces waste, and

 Difficult to Change Over

This event can bring high costs for

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