lean Manufacturing

Presented by :

Abhinav
Gaurav Kumar
Dft-VII

lean manufacturing

01

Lean manufacturing or lean production,

often simply "lean", is a systematic
method for the elimination of waste
("Muda") within a manufacturing system.

LEAN TOOLS

KPIs (Key Performance Indicators)

Muda (Waste)
Overall Equipment Effectiveness (OEE)
PDCA (Plan, Do, Check, Act)

5S
Andon

Poka-Yoke (Error Proofing)

Root Cause Analysis

Bottleneck Analysis

Single-Minute Exchange of Dies (SMED)

Continuous Flow

Six Big Losses

Gemba (The Real Place)

SMART Goals

Heijunka (Level Scheduling)

Standardized Work

Hoshin Kanri (Policy Deployment)

Jidoka (Autonomation)
Just-In-Time (JIT)
Kaizen (Continuous Improvement)

Kanban (Pull System)

Value Stream
Mapping
Visual Factory

Takt Time
Total Productive Maintenance (TPM)

02

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Value Stream Mapping

A tool used to visually map the flow of

production. Shows the current and
What
is Value
Mapping?
future
state Stream
of processes
in a way that
highlights opportunities for
improvement.
A value stream involves all the steps,
both value added and non value added,
required to complete a product or
service from beginning to end.
04

How does Value Stream Mapping help?

Exposes waste in the current

processes and provides a
roadmap for improvement
through the future state.

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Value Stream Mapping Purpose

06

Provide optimum value to the

customer through a complete
value creation process with
minimum waste in:
Design (concept to customer)

Build (order to delivery)

Sustain (in-use through life cycle to service)

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It is a representation of the flow of materials from

supplier to customer through an organization as well
as the flow of information.
This enables us to see at a glance where the delays
are in process, any restraints and excessive
inventory.
The current state map is the first step in working
towards ideal state for our organization.

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Applications

09

Value stream mapping has supporting methods that are

often used in Lean environments to analyze and design
flows at the system level (across multiple processes).
Although value stream mapping is often associated with
manufacturing, it is also used in logistics, supply chain,
service related industries, healthcare, software
development, product development, and
administrative and office processes.

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Two key metrics associated with value

stream mapping are value adding times
and non value adding times. Non value
adding time is called waste or muda.

Using the Value Stream Mapping Tool

11

Scoping the
Value Stream

Determine the Value Stream

to be improved

Current State
drawing

Understanding how things

currently operate. This is
the foundation for the future
state.

Future State
drawing

Designing a lean flow through the

application of Lean principles

Planning and
Implementation

The goal of mapping!

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First stage is to determine how much value

addition is taking place for one line starting
from fabric store to final dispatch.

In order to make VSM for a production line, list of activities carried out in sequential
order are as follows:
13

1
Time Study for all the
operations for a
particular style.

2
Recording WIP present in
each department & in
between two departments.

4
Calculating DHU
percentage for each
department.

Calculating machine
reliability for all the
available machines.

Calculating FTT data for

each line.

Created VSM for all 6 lines &

MTM:

14

-Collected WIP details in all sections &

between the sections
-Collected DHU% data
-Collected M/c Breakdown%
data
-Did time study for all operations

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Current VSM

Calculated VA% time & lead time for all lines.

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This study is been done for production lines and findings of the
study in sequential order are as follows:

60

3.00%

50.37 52.3 50.57

50
46.09

2.50%

45.71
38.9

40

2.00%

No of Days 30

1.50%

20

1.00%

10

5.07 0.50%

0.00%

Lead time (days)

5
VA%

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Future VSM

Advantages

19

it ties together lean

concepts and techniques,
which helps you avoid
cherry picking.

It shows the linkage between

the information flow and the
material flow. No other tool
does this.

It provides a common
language for talking about
manufacturing processes.

It helps us see more than

waste. Mapping helps you
see the sources of waste in
value stream.

It helps visualize more than

just the single-process level,
i.e. assembly, finishing, etc.,
in production. You can see
the flow.

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Visual Management

What is Visual Factory?

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Visual indicators, displays and controls

used throughout manufacturing plants
to improve communication of
information.

How does Visual Factory help?

Makes the state and condition of
manufacturing processes easily
accessible and very clear to
everyone.
It makes the information flow
between different departments easy,
by visual displays

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Line wise colour coding & hourly loading

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Line wise colour coding

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THANK YOU VERY MUCH