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LEAN MANAGEMENT By V K Saxena SPME/NAIR 1

Lean Management - SPME.pptx

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LEAN MANAGEMENTBy V K SaxenaSPME/NAIR1Basic Advance2Some Deni!ionsInven!o"yInven!o"yis a## !$e money!$a! !$e sys!em$as inves!ed in %&"c$asin' !$in's ($ic$ i! in!ends !o se##)%e"a!in' Ex%ensesA## !$e money!$a! !$e sys!ems%ends in o"de" !o !&"n inven!o"y in!o !$"o&'$%&! T$"o&'$%&!T$"o&'$%&! is !$e "a!e a! ($ic$ !$e sys!em 'ene"a!e money !$"o&'$ sa#esDeni!ions !a*en +"om T,E Goa#- .y E#iya$&M Go#d"a!!/What is Lean Management ?LeanisaMan&+ac!&"in'o"mana'emen! %$i#oso%$y !$a! s$o"!ens !$e #ead !ime .e!(een ac&s!ome"so"de"sands$i%men!o+!$e%a"!s o"se"viceso"de"ed!$"o&'$e#imina!iono+a## +o"ms o+ (as!e 01a%anese name M2DA34Lean$e#%sin"ed&c!iono+cos!5cyc#e!imeand non va#&e added ac!ivi!ies46,is!o"y )+ Lean Mos! o+ !$e #ean conce%!s a"eno! ne(4 Many o+ !$em(e"e.ein'%"ac!iceda!7o"dMo!o" 8om%anyd&"in'!$e192:so"a"e+ami#ia"!o mos! ind&s!"ia# en'inee"s4 A+e(yea"sa+!e";o"#d;a"II5Ei,is!o"y )+ Lean T$econce%!sand!ec$ni?&es!$a!'oin!o!$is sys!ema"eno(*no(nasToyo!aP"od&c!ion Sys!em0TPS35and(e"e"ecen!#y"ein!"od&ced and%o%a"ised.y1ames;omac*=s'"o&%in !$e2ni!edS!a!es&nde"!$e&m."e##ao+#ean man&+ac!&"in'4Leanconce%!sa"ea%%#ica.#e.eyond!$es$o% @oo"48om%anies$ave"ea#iAed'"ea!.ene!.y im%#emen!in'#ean!ec$ni?&esin!$eoBce +&nc!ionso+man&+ac!&"in'"ms5as(e##asin %&"e#yse"vice"mss&c$as.an*s5$os%i!a#s5 and"es!a&"an!s4Leanman&+ac!&"in'in!$is con!ex! is *no(n as Lean enterprise.CSome %"o!Bi''e" %"o!8os! !o %"od&ceP"ice !o se##Inc"ease %"o! .y P"ice Inc"easeBut, may lose customers!DSome %"o!Bi''e" %"o!8os! !o %"od&ceP"ice !o se##Inc"ease %"o! .y 8os! Red&c!ionET,REE TFPES )7 A8TIVITIESN)N VAL2E ADDING98"i!e"ia o+ Va#&e Added ac!ivi!y1:8&s!ome" is (i##in' !o %ay8$an'e/T"ans+o"ma!ion is !a*in' %#aceRi'$! "s! !ime8anvas ATMP"od&c!ivi!y Inc"ease P"od&c!ivi!y inc"ease is no! d&e !o mo"e (o"*5 .&! "a!$e" .y minimiAin' (as!es4 Decrease of Wastes Increase by More WorkVa#&e Added %a"! (i## .e .i''e" in %"o%o"!ion !o !$e (as!es;as!e and Va#&e Added (i## .e inc"eased !o !$e same %a"!4Pa'e 11Before AfterLead Times and ;as!e S$o"! #ead !imes (i## .e ac$eived .y conse?&en! "ed&c!ion o+ (as!es in !$e %"ocess4 Va#&e Added ;as!e Va#&e Added ;as!eTime TimePa'e 12T$e Seven Kinds o+ ;as!eproductionenvironmentArea / SpaceRe(o"*1/)ve"-%"od&c!ion)ve"-%"od&c!ion is !$e #eadin' ca&se o+ (as!eRoo! ca&ses 2ns!a.#e %"ocesses 8om%ensa!ion .ased on %"od&c!ion vo#&me An!ici%a!ed %"od&c!ionRes!s P"od&c!ion +o" inven!o"y inc"eases $and#in' cos! Inc"eased inven!o"y o+ semi-nis$ed and nis$ed %"od&c!s 8os! o+ inven!o"y P"od&c!ion ca%aci!ies a"e "es!"ic!edPa'e 16Inven!o"y ,i'$ inven!o"ies $ide %"o.#ems and can inc"ease #ead !imes4 Roo! ca&ses Poo" sc$edin' ,idin' o+ &ns!a.#e %"ocesses ,i'$ va"ie!y o+ %"od&c!s Res!s ,i'$ adminis!"a!ion cos!s S!o"a'e #imi!a!ions P"od&c!ion !$a! dec"eases ca%aci!y P"od&c!s can .e dama'ed Sc"a%%in' o+ !oo $i'$ inven!o"ies444 Addi!iona# ma!e"ia# movemen!sPa'e 1>8on!in&a# Im%"ovemen!Easy Iden!ica!ionNecessi!y o+ a +as! %"o.#em so#vin' Se! ;o"*s$o%s and %"oS in adminis!"a!ive A"eas &nnecessa"y doc&men!s e4'4 ca!a#o'5 +o"ms5 #esN)(nK oBce s&%%#y s!o"a'e s!o"a'e sys!em ma"*ed @oo" s%acesmanda!o"y d"ive s!"&c!&"ea#(ays c#eaned %#an! and oBce +&"nis$in's c#ean oBces and .&i#din's se! &% a c#eanin' %#an8#ean Des* Po#icyseiri seiton, seisoseiketsushitsuke /17L);S%a'$e!!i Dia'"amMa!e"ia# Movemen!Doc&men! Movemen!Pe"son Movemen!Pa'e /28ELL Man&+ac!&"in'Pa'e //8a""yin' o&! one-%iece-a!-a-!ime%"ocessin' in o"de" !o e#imina!es!a'na!ion o+ (o"* 0?&e&e3 in and.e!(een %"ocessin' s!e%s41ellAn a""an'emen! o+ %eo%#e5sys!ems5 i!ems5 and me!$ods (i!$!$e %"ocessin' s!e%s %#aced "i'$!nex! !o eac$ o!$e" in se?&en!ia#o"de"5 !$"o&'$ ($ic$ %a"!s a"e%"ocessed in a con!in&o&s @o(4AB8AB8KANBANPa'e /6;$a! is Kan.anJ Kan.an is a 1a%anese (o"d meanin' Kdis%#ayL o"Kins!"&c!ion ca"dL o" KSi'na#LJ I! is a ca"d desc"i.in' !$e %a"! n&m.e"5 !$e ?&an!i!y o+ %a"!s5 ($e"e !$ey a"e +"om5 !o ($e"e !$ey a"e !o .e de#ive"ed5 and so on4 P#Sys!em8$e?&e Boo*TPMPa'e />)4E4E-)ve"a## E?&i%men! EBciency8om.ina!ion o+ !$"ee 7ac!o"s Avai#a.i#i!yPe"+o"manceG&a#i!y )%e"a!o" o(ne"s$i% C:O B"ea* do(n P"oo! ca&se- 8LIT8#ean5 L&."ica!ion5Ins%ec!ion5Ti'$!enin'Exam%#eTo!a# $o&"sH EAvai#a.#e $o&"sHC,o&"#yo&!%&!H1::So To!a# o&!%&!HE::Avai#a.#e o&!%&! HC::Pe"+o"manceH>::G&a#i!y o&! %&!H6::Avai#a.#e Ra!ioH C::/E::Pe"+o"mance Ra!ioH >::/C::G&a#i!y Ra!ioH6::/>::)4E4EH 6::/E::H >:OIt is an approach for mistake-proo2ng processesusingautomaticdevicesor methods to avoid simple human error"/C3AI45KAI/D/EConcept of 3M/ Ty%e o+ ;as!e/96:M6+I 7 .(+AI5M6+A7 I51,5.I.(518 * IMBALA51M6DA 7 WA.(& M69sMudaMuraMuriM6+I : 6nreasonable *IrrationalM6+A : ;luctuationSync$"oniAa!ion (i!$ 8&s!ome"s ;o"*in' sync$"ono&s !o !$e c&s!ome" !a*! is .ased on !$e +o&" Lean-P"inci%#esQ 7#o(5 Ta*!5 P# and Re"o-de+ec!;lo A1= W,+3 =A. (, PA.. (=+,6>=+IDI16L? ,PP,.I(I,5A5D(=5 A11P(A51".WAMI !I!3A5A5DT,ANKS66