Lean Mnufacturing-What it can do for your company?

Good morning all, I am  Rupesh Deshmukh (Mechanical Engineer)

Today's our topic is the basics of Lean manufacturing.

First why lean manufacturing required to earn profit. Now a days very high competition during modern age of technology. to fulfill the need of Customer very good Quality, lowest Cost, on time delivery. All industries are facing the challenge of reduce cost by improving quality.
All these requirements are fulfill by Lean manufacturing  and industry can earn more profit.




What is mean by Lean?


Lean manufacturing or lean production, often simply "lean", is a systematic method for the elimination of waste within a manufacturing system.
Elimination of Muda-Waste
                        Muri- Overburden
                        Mura-Unevenness
Working from the perspective of the client who consumes a product or service, value added work.

                                                Model of Lean production system




Types of waste-

Transport -(moving products that are not actually required to perform the processing)

Inventory -(all components, work in progress and finished product not being processed)

Motion -(people or equipment moving or walking more than is required to perform the processing)

Waiting (waiting for the next production step, interruptions of production during shift change)

Overproduction (production ahead of demand)

Over Processing (resulting from poor tool or product design creating activity)

Defects (the effort involved in inspecting for and fixing defects)^[

Steps to achieve lean systems

The following steps should be implemented to create the ideal lean manufacturing system:^[37]

• Design a simple manufacturing system
• Recognize that there is always room for improvement
• Continuously improve the lean manufacturing system design

Lean Manufacturing tools:

5S :Organize the work area

• Sort (eliminate that which is not needed)
• Set In Order (organize remaining items)
• Shine (clean and inspect work area)
• Standardize (write standards for above)
• Sustain (regularly apply the standards)

Eliminates waste that results from a poorly organized work area (e.g. wasting time looking for a tool).

Andon::

Visual feedback system for the plant floor that indicates production status, alerts when assistance is needed, and empowers operators to stop the production process.

Acts as a real-time communication tool for the plant floor that brings immediate attention to problems as they occur – so they can be instantly addressed.

Bottleneck Analysis :

Identify which part of the manufacturing process limits the overall throughput and improve the performance of that part of the process.

Improves throughput by strengthening the weakest link in the manufacturing process.

Continuous/single piece Flow:

Manufacturing where work-in-process smoothly flows through production with minimal (or no) buffers between steps of the manufacturing process.

Eliminates many forms of waste (e.g. inventory, waiting time, and transport).

TPM Equipment reliability:

Total productive maintenance is the best tool which help for maintenance of equipment  that  aims  at achieving  an  optimal  production environment  devoid  of  defects,  downtime,  stoppages and accidents.

Kanban:

Kanban means card information. Kanban is an inventory control system to control the supply chain.

Types of kanban systems-

Production (P) Kanban:

Transportation (T) Kanban

SMED: Single minute exchange of die

 It provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product. This rapid changeover is key to reducing production lot sizes and thereby improving flow.

The phrase "single minute" does not mean that all changeovers and startups should take only one minute, but that they should take less than 10 minutes (in other words, "single-digit minute").

FMEA-Failure Mode Effects Analysis

it is a step-by-step approach for identifying all possible failures in a design, a manufacturing or  assembly process, or a product or service.

“Failure modes” means the ways, or modes, in which something might fail

“Effects analysis” refers to studying the consequences of those failures

Value stream mapping

 It is a lean-management method for analyzing the current state and designing a future state for the series of events that take a product or service from its beginning through to the customer. At Toyota, it is known as "material and information flow mapping".

Poka yoke

It is a Japanese term that means "mistake-proofing" or “inadvertent error prevention”. A poka-yoke device is one that prevents incorrect parts from being made or assembled, or easily identifies a flaw or error.

Kaizen

Kaizen, means  "improvement." When used in the business sense and applied to the workplace, kaizen refers to activities that continuously improve all functions and involve all employees from the top management to operator. It is nothing but change for better.

Advantages of Lean Manufacturing

• Improved quality 

• Improved Visual Management

• Increased efficiency

• Manpower reductions

• Easier to manage

• Total Company Involvement

• Problem Elimination

• Reduced Space

• Safer Work Environment

• Improved employee morale

Thank you All for reading.in the next blog we can go in details with live industry example.