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Lean Manufacturing - Article Description

Author Name: Mayuri Gupta

About The Author
Persuing MBA (final yr) from St Ann's PG College, very ambitious, carrer oriented. Completed graduation in Biotechnolgy.

Lean Manufacturing
Lean manufacturing is a manufacturing philosophy, which shortens the time line between the customer order and the product shipment by eliminating waste. Waste is anything that adds cost to the product without adding value there are two types of waste unavoidable waste and avoidable waste PRINCIPLES OF LEAN The five-step thought process for guiding the implementation of lean techniques is easy to remember, but not always easy to achieve: 1.Specify value from the standpoint of the end customer by product family. 2.Identify all the steps in the value stream for each product family, eliminating whenever possible those steps that do not create value. 3.Make the value-creating steps occur in tight sequence so the product will flow smoothly toward the customer. 4.As flow is introduced, let customers pull value from the next upstream activity. 5.As value is specified, value streams are identified, wasted steps are removed, and flow and pull are introduced, begin the process again and continue it until a state of perfection is reached in which perfect value is created with no waste. 7 types of waste are - 1) Waste of transportation 2)Waste of inventory 3) Waste of motion 4) Waste of waiting 5) Waste of overworking 6) Waste of over production 7) Waste of defects. Lean tools are - •5S •KAIZEN •Total Productive Maintenance (TPM) •Policy Deployment Matrix (PDM) •Value Stream Map (VSM) 5S EVENTS 5s events is a method for organizing a workplace, especially a shared workplace (Shop floor/ Office) and keeping it organized. S1 sorting S2 systematic arrangement S3 shine S4 standardise S5 sustain The core idea is to maximize customer value while minimizing waste. Simply, lean means creating more value for customers with fewer resources. A lean organization understands customer value and focuses its key processes to continuously increase it. The ultimate goal is to provide perfect value to the customer through a perfect value creation process that has zero waste. To accomplish this, lean thinking changes the focus of management from optimizing separate technologies, assets, and vertical departments to optimizing the flow of products and services through entire value streams that flow horizontally across technologies, assets, and departments to customers. Eliminating waste along entire value streams, instead of at isolated points, creates processes that need less human effort, less space, less capital, and less time to make products and services at far less costs and with much fewer defects, compared with traditional business systems. Companies are able to respond to changing customer desires with high variety, high quality, low cost, and with very fast throughput times. Also, information management becomes much simpler and more accurate. "Lean Manufacturing" concepts provide an excellent approach for resolving this dilemma. One of the major focuses and results of Lean Manufacturing is task reduction! Once implemented, Lean Manufacturing takes less work to get the job done daily. You can see this in the results typically seen in manufacturing companies that have successfully implemented Lean Manufacturing techniques. Successful Lean Manufacturing typically means achieving amazing results like: 1) Inventory turns doubling and tripling (WIP inventory is spinning rapidly – a minimum of 80 to 100 times per year). 2) Velocity, flexibility, and responsiveness of manufacturing increasing – adjusting manufacturing to the customer, not adjusting the customer to manufacturing. 3) Massive cost reduction – 30% to 50%. 4) Significant process productivity improvements. The ability to produce more with the same or fewer resources.



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