7/27/2019 Lean Seminar PPT

1/17

By

Saurabh Gautam

29274

B.Tech 3rd Year

Mechanical Engineering

Welcome to a Presentation on

Lean Manufacturing

7/27/2019 Lean Seminar PPT

2/17

Introduction

Definition

A production practice which aims at detection and

removal of wastes from manufacturing and completing

the job at minimum cost.

Figure 1

7/27/2019 Lean Seminar PPT

3/17

Historical Background

Originated by Toyota in 1950s

Developed jointly by Taiichi Ohno and Shigeo Shingo

Based on the philosophy of Preserving value withless work

Initially known by the name Just-in-Time (JIT)

production

Later came to be known as Toyota Production System Lean Manufacturing is the latest name of JIT

7/27/2019 Lean Seminar PPT

4/17

Just-in-Time Production

7/27/2019 Lean Seminar PPT

5/17

System

The 8 wastes

Figure 2

7/27/2019 Lean Seminar PPT

6/17

Mechanism of Lean Manufacturing

Lean Building Blocks

Pull System

Kanban

Figure 3

Figure 4

7/27/2019 Lean Seminar PPT

7/17

Continued

Work Cells

Concurrent Engineering

Figure 5

Figure 6

7/27/2019 Lean Seminar PPT

8/17

Continued

5S or Workplace Organisation

Figure 7

7/27/2019 Lean Seminar PPT

9/17

Continued

Batch Size Reduction

Quick Changeover

Total Productive MaintenanceTotal Quality Management

Visual Controls

7/27/2019 Lean Seminar PPT

10/17

The TPS House

Figure 8

7/27/2019 Lean Seminar PPT

11/17

Analysis of Lean Manufacturing

through some Industrial Case Studies

Case Study 1: Internationalization of Honda Motor Co.

Honda is the famous Japanese multinational

company

It was established in 1948

Manufactures automobiles, motorcycles and lawn

mowers

Presently has 119 manufacturing facilities in 33

countries

Figure 9

7/27/2019 Lean Seminar PPT

12/17

7/27/2019 Lean Seminar PPT

13/17

Continued

Honda changed its manufacturing philosophy toLean in the mid 1990s to make its production

more flexible.

It was able to build different, cheap cars for

different markets and yet achieved economies of

scale.

Honda showed how productivity can be increased

without increasing the input cost by implementing

the Lean Manufacturing System (LMS).

Just a slight change in the production

methodology has made Honda one of the

greatest competitors in the car-industry.

7/27/2019 Lean Seminar PPT

14/17

Case Study 2: Lean manufacturing and EMS in the

Shipbuilding Sector

Environmental Management System(EMS) has

become an integral part of the manufacturing

sector.

Lean and EMS are different yet complimentary toeach other.

Shipbuilding companies divide wastes in two

categories-

Type 1(unnecessary) and Type 2(necessary).

Through EMS, these companies try to reduce

type-2 wastes.

Implementation of Lean with EMS

7/27/2019 Lean Seminar PPT

15/17

Benefits of Lean Manufacturing

Lead Time reduced by 90%

Productivity increased by 50%

Work-in-Process Inventory reduced by 80%

Space utilization reduced by 75%

Quality improved by 80%

Reduction in Order processing errors

Streamlining of processes

Reduced lead-time allows for various strategic

improvements in the organisation.

7/27/2019 Lean Seminar PPT

16/17

Conclusion

Lean organizations are more responsive tomarket trends.

They deliver products and services faster in an

economical and inexpensive manner.

It not only reduces work-in-process inventory but

also lot sizes which increases inventory turns.

It reduces material handling distances and rapid

feedback from downstream work-centres.Results in continually declining costs, zero

defects, low inventories and endless product

variety.

7/27/2019 Lean Seminar PPT

17/17

Thank You