Lean Manufacturing - Concept, Tools & Quality Management
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Transcript of Lean Manufacturing - Concept, Tools & Quality Management
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Lean Manufacturing Concepts and Tools and Quality ManagementBy Hristina Koycheva
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What is Lean?Lean is an Operational Excellence Strategy that enable you to change for the better- in fact the Japanese often use Kaizen which use by lean practitioners to describe incremental improvements ;
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What is Lean?Persistent process in elimination of waste MUDA describes any activity thats done, but add no real value to the product or service.
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What is Lean?Respect for peopleHigh Quality and Stable Processes
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Where?At all level there is a strong desire to be better;A culture of lean is visibly prioritised and practice from the top to the bottom of the workforce;The key is understanding the customer and delivering his requirements;
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How?Improves business performance using simple practical tools and techniques to enhance quality, cost, delivery and people contribution;Exposes the wastes in the system;People need to change their long standing work practices and ideas;Senior management need to drive lean principles forward with total commitment to its success;Not a bolt on technique, more a way of life leading to a total change in culture.
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Short History1913: Henry Ford (Start of mass manufacturing with the moving line)
1938 JIT Born
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Short History1950: Eiji Toyoda brings the ideas of continuous moving line in Japan
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Short History1960: Toyota production System, main principles of lean manufacturing
1991: Lean Management
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Main PrincipalsIdentify the customerMap the flowMake a product or service flowCreate polls based on customer demandsContinually find ways to improve
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Lean ToolsAssessment and planning- fundamentals and understanding where we are today and creating and design for tomorrow.
Plan, Do, Check, Act
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Lean Tools5 S
Visual control
Standardize work
Total productive maintenance
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Select the keyReduce cost of production
Increase customer satisfaction
Improve qualitySelect the keyMap Process
Eliminate Waste
Make Process Flow
Establish Customer Poll
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What Is Waste?Waste of overproduction (largest waste)Waste of time on hand (waiting)Waste of transportationWaste of processing itselfWaste of stock at handWaste of movementWaste of making defective products
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Lean ThinkingKey Principals of Lean ThinkingValue - what customers are willing to pay for;
Value Stream the steps are delivered value;
Flow organizing Value Stream to be continuous;
Polls responding to downstream customer demand;
Perfection relentless continuous improvement (culture);
Lean Thinking, Womack and Jones,1996
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ConclusionLean is:
A systematic approach to identifying and eliminating waste (non-value added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection.
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Production SystemTwo pillars:
Jidoka
Just-in-time
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What is Jidoka?Jidoka means autonomous. The responsibility of each associate to deliver Quality to the customers.- Intense Motivation Training;- Explained Information;
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Just-in-timeAims of zero inventory;
Parts are not kept in warehouse;
Parts arrive when needed;
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Quality systemQuality means compliance with specifications- no less, no more;No need for inspections!
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Quality AssuranceWhen we focused on this we will consistently deliver what the customer expects;
Trust raises everyones commitment
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Thank you!