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Lean MFG

Lean manufacturing focuses on eliminating waste from the manufacturing process. Waste is defined as any activity that does not add value from the customer's perspective. Lean aims to systematically eliminate waste through principles like continuous improvement, respect for employees, levelized production, and just-in-time production. Performance measurement is important for lean manufacturing to monitor efficiency and effectiveness, identify improvement opportunities, and align behaviors. Agile manufacturing enables rapid response to customers by integrating organization, people, and technology to quickly deliver personalized products. It is effective for manufacturers in developed markets by leveraging proximity to deliver speed and customization that offshore competitors cannot match.

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52 views

Lean MFG

Lean manufacturing focuses on eliminating waste from the manufacturing process. Waste is defined as any activity that does not add value from the customer's perspective. Lean aims to systematically eliminate waste through principles like continuous improvement, respect for employees, levelized production, and just-in-time production. Performance measurement is important for lean manufacturing to monitor efficiency and effectiveness, identify improvement opportunities, and align behaviors. Agile manufacturing enables rapid response to customers by integrating organization, people, and technology to quickly deliver personalized products. It is effective for manufacturers in developed markets by leveraging proximity to deliver speed and customization that offshore competitors cannot match.

Uploaded by

Asma Khan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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*Future Trends

in
Manufacturing
System
Lean Manufacturing

What is Lean?
The core idea of lean manufacturing is
actually quite simplerelentlessly work on
eliminating waste from the manufacturing
process.
So what is waste?
Waste is defined as any activity that does not
add value from the customers perspective.
Lean Manufacturing

Lean manufacturingorlean production,


often simply "lean", is a systematic method for
the elimination of waste within a
manufacturing system. Lean also takes into
account waste created through overburden
and waste created through unevenness in work
load.
Lean Manufacturing
Principles
oElimination of Waste

oContinuous Improvement

oRespect For Humanity


The most valuable resource to any company are
the people who work for it. Without these people
the business does not succeed. When people do not
feel respected, they tend to lose respect for the
company.
Lean Manufacturing
Principles
(Conti.)
oLevelized Production
The foundation of lean manufacturing is
levelized production. The basis of this principle
is that the work load is the same (or level)
every day.
oJust In Time Production
The basis behind this principle is to build
what is required, when it is required and in
the quantity required.
Focus on Waste
SEVEN WASTES
Relation of Waste to
Profit
oYouve probably heard of the 5S methodology
that makes up the foundation of lean
manufacturing, but in todays volatile industry it
seems only one S matters: survival.
oA still-recovering economy means survival is the
key word on the minds of most small and
medium-sized business operators as they look to
cut waste and maximize profit.
Continuous
improvement

MAKE THINGS BETTER


Philosophy of Continuous
Create constancyImprovement
of purpose toward improvement of
product and service, with the aim to become
competitive and to stay in business and to provide
jobs.
Adopt the new philosophy.
Eliminate the need for inspection on a mass basis by
building quality into the product in the first place.
End the practice of awarding business on the basis of
price tag. Instead, minimize total cost.
Improve constantly and forever the system of
production and service to improve quality and
productivity and thus constantly decrease costs.
Institute training on the job.
Institute leadership. The aim of supervision should
be to help people and machines and gadgets to do a
better job.
Drive out fear so that everyone may work effectively
for the company.
Break down barriers between departments. People in
research, design, sales and production must work as a
team to foresee problems of production and use of
the product or service.
Eliminate asking for zero defects and new levels of
productivity. Such exhortations only create adversarial
relationships as the bulk of the causes of low quality
and low productivity belong to the system and thus lie
beyond the power of the work force.
Remove barriers that rob people in
management and in engineering of their right to
pride of workmanship.
Institute a vigorous program of education and
self-improvement.
Put everybody in the company to work to
accomplish the transformation. The
transformation is everybody's job.
Four Functions of Lean Manufacturing

1. Production Flow
oProducts,workflow,equipmentand support
oIt is focused on defining products, equipment and workflows that can be
produced insmalllotproduction runs being pulledbydownstream
customerdemands
oIt is oriented to getting the product to the customer in the shortest period
of time and at the lowest cost with superior quality and customer
satisfaction
2. Planning
oThe separation of:
MRPSystem function: (Reconciliation the process ofhigh-level demand
planning and scheduling)form
Day-to-dayplanning functions (Regulation the process of regulating command
and control sequences within apull-processenvironment capable of controlling
workable work for each production unit and production cell.
oMRPmust also project intermediate and long-range procurement objectives
3. Organization
* Lean Production demands a re-thinking of the structure, role and
responsibility of each individual within the organization.
* The formation of Production Units operating as BusinessUnits
&FlatOrganizationwill help to understand the needs of their
customers and organize all resources, products and capabilities to
support and add value to its customers needs and
expectations.
4. Performance Measures
* Performance Measures must be developed in a hierarchy that is
cascaded upward and downward within the organization.
* The measures should be understandable, simple to administer and
enable management and team members to easily make decisions and
take action when appropriate.
Performance Measures
Why Measure ?

What is performance measurement?


Performance measurement is the process of
measuring efficiency, effectiveness and capability, of
an action or a process or a system, against given norm
or target.
Role of Performance
Measurement
Monitoring
Measuring and recording actual performance
Control
Identifying and attempt to close the gap between planned target and
actual performance
Improvement
Identify critical improvement opportunities
Coordination
Internal communication across processes
External communication with stakeholders
Motivation
Align Behavior and encourage transformation
Metrics
Strategic Metrics
Net Operating Profit
Inventory Turnover
Cash flow
Market Position
Efficiency metrics and Lagging indicators
Tactical Metrics
Costof quality
Productivity
Accuracy and timeliness of reporting and control
Operational Metrics
Safety
Quality
Environment
Delivery
Value Delivery Metrics
On time delivery
Customer satisfaction and loyalty
Employee Satisfaction
New product Introduction
Value of the Product

An assessment of the worth of a good or


service.
INTRODUCTION
TO
AGILE MANUFACTURING

oAgile manufacturing is a method for manufacturing


which combine our organization, people and
technology into an integrated and coordinated
whole.
oAgile manufacturing represents a very interesting
approach to developing a competitive advantage in
todays fast-moving marketplace. It places an
extremely strong focus on rapid response to the
customer turning speed and agility into a key
competitive advantage.
*Why is agile manufacturing
an effective strategy?
oConsumers love choice. They prefer to
get a product exactly as they want it
without compromise.
oConsumers are fickle. Their interests shift
and move in unpredictable ways.

Agile is effective because it directly


addresses these issues.
AGILE MANUFACTURING
oAgile Manufacturing acknowledges the realities of
the modern marketplace and transforms them into
a competitive advantage.
oAgile is of particular value for manufacturers in
countries with large, well-developed local markets
and high labor costs (e.g. the United States). It
leverages proximity to the market by delivering
products with an unprecedented level of speed
and personalization, which simply cannot be
matched by offshore competitors. It turns local
manufacturing into a competitive advantage.

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