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My Presentation

Presentation by :Sumon Kumar Kundu

ExecutiveIndustrial Engineering

DepartmentEpyllion Group

Topic: Lean Waste

Lean manufacturingA systematic approach to identifying and

eliminating waste (non value added activities ) through continues improvement by flowing the product at the pull of customers in pursuit of perfection.

Lean is a term to describe a system that produces what the customers want ,when they want it , with minimum waste.

Lean manufacturingLean manufacturing is a culture.

Lean manufacturing is the wheel of JIT(Just In Time)

Objectives of Lean Manufacturing

Elimination of waste in following areas: 1.Extra Work force. 2.Outsourcing. 3.Overtime. 4.Air shipment.

Mostly used in production based factory management

WasteWaste is anything that does not contribute to

transforming a part to the customer’s needs.

Essentially, a “waste” is anything that the customer is not willing to pay for.

ACTION FOR REDUCING WASTE1.Waste can be 100% eliminated

2.Waste can be reduced or simplified

TYPEs OF WASTE8 types of waste

01. Overproduction 02. Over processing 03. Rework

04.Waiting05. Excess inventory06. Excess motion07. Excess transportation08. Disconnectivity

OVER PRODUCTIONRunning a machine to produce product that is

not needed for next process.

Means making more than is required by the next process, making earlier than is required by the next process or making faster than is required by the next process.

Causes of overproduction wasteWrong Takt time Long process setup Unleveled schedule Unbalanced work load

OVER PROCESSINGDoing more work than necessary to meet the

customer needs or requirements

Doing more detailed information than necessary

Sometimes it is keep busy work

Causes of over processingProduct change without process changesLack of communicationsRaw material approvalsRely on paper and extra copies

REWORKMeans any repair or additional work performed

outside the operators normal work.Reworks are- Pieces of needles in product Fabrics non adequate to

specifications Wrong size or fit Pieces cut wrong Incorrect information Drawn incorrectly

CAUSES OF REWORK WASTE

Weak processes control.Poor quality.Unbalanced inventory level.Deficient planed maintenance.Inadequate education or training.Customer needs not understood.

WaitingAny idle time which is not spent for

performing work for goods or servicesIt may be- for the next product for the materials for the assistant for equipments for information

CAUSEs OF WAITINGTimes Unbalanced work loadUnplanned maintenanceLong process set upUpstream quality problemUnleveled scheduling

Excess inventory or WIP• Material between operations due to large lot

production or processes with cycle time. • Material sits taking up space, costing money

and potentially being damaged.• It may be- Raw materials in storage

Materials and supplies in storage. Materials at the process Finished goods stored prior to shipping.

Causes of Excess Inventory or WIPProduct complexityUnleveled schedulingUnbalanced work loadUnreliable shipments by suppliersMisunderstood communications

Excess motionAny motion that does not add value to the product is

wasteMotion of the workers, machines, and transport(due

to the inappropriate location of tools and parts )It may be- Walking from point to point during the

work cycle. Reaching to pick materials. Turning or bending. Matching parts. Repeat evacuation motion. Excessive travel distance.

Causes of motion wastePoor people ,machine effectiveness.Inconsistent work methods.Unfavorable facility or cell layout.Poor workplace organization and house

keeping.Extra “busy” movements while waiting.

Excess transportation wasteMoving the materials which does not enhance

the value of the product to the customers.It may be- The movement of materials, weather

manual or automatic. Moving materials to and from the

warehouse. movement of materials at the process.

Handling and carrying paper work between operations.

CAUSEs OF EXCESS TRANSPORTATION WASTE Poor plant layout.Poor understanding of the process flow for

production.Large batch sizeLong lead time.Large storage areas

Under utilizing people or Disconnectivity. It means that not taking advantages of

peoples abilities.

Causes of disconnectivityOld guard thinking , politicies , the business

culture.Poor hiring practices.Low or no investment on training.Low pay , high turn over strategy

Function of waste reductionLabor utilization- to maximize labor

working time.Machines utilization- to maximize machines needles

downtime.Space utilization- to reduce cost related to

WIP, Inventories

Steps for waste eliminationMotivation Follow the “Just In Time” manufacturing

process.Use correct automationSchedule will be leveledBalanced workloadAppropriate quality inspection.Proper line balancingWell market forecastCommunication will be very good between management level and workers.

Waste reduce toolsMaintain 5S.Visual control systems.Quick change over.Cellular manufacturing by team work.Total Productive Maintenance.Kanban.Kaizen .Mistake proofing.

Thanks ToAll

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