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LEAN Production

Md. Shafiul Alam Chowdhurytanzeem772@gmail.com

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Lean Production

• Less time, inventory, space, labor, and money

• eliminating waste, simplifying procedures and speeding up production.

• also known as Toyota Production System

• Toyota was able to greatly reduce leadtime and cost using the TPS (Toyota Production System), while improving quality at the same time

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Lean Production

Systematic elimination of the 7 types of waste:

• Overproduction• Waiting• Transportation• Inventory• Motion• over-processing, • defective products

The japanese call it Muda (in Eng: Wastage)

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Benifits

• Waste reduction by 80%

• Production cost reduction by 50%

• Manufacturing cycle times decreased by 50%

• Labor reduction by 50% while maintaining or increasing throughput

• Inventory reduction by 80% while increasing customer service levels

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Benifits

• Capacity in current facilities increase by 50%

• Higher quality

• Higher profits

• Higher system flexibility in reacting to changes in requirements improved

• More strategic focus

• Improved cash flow through increasing shipping and billing frequencies

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Kaizen

• philosophy of continual improvement

• involving everyone – managers and workers Management has two major components:

• maintenance, and • improvement

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Poka-Yoke

• defect warning system

• make it impossible to make mistakes

• initial term was baka-yoke, which means ‘fool-proofing’

• improve quality and reliability

• can eliminate both human and mechanical errors

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Kanban

• to achieve Just-in-time

• pulls just the number and type of components the process requires

• physical card or other devices

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Kanban card

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Jidoka

• meaning “automation with a human touch”

• quality control process • four principles:

• Detect the abnormality • Stop • Fix or correct the immediate condition• Investigate the root cause and install a

countermeasure

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Jidoka

• Jidoka involves the automatic detection of errors or defects during production

• helps to detect a problem earlier and avoids the spread of bad practices

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