LEAN MANUFACTURING

MINOR PROJECT ON LEAN IMPLEMENTATION PLAN

SUBMITTED BY:
ABDUL QADIR KHAN(01)
HIMANSHU KUMAR (11)
RAJANI KANT GAUTAM (24)
OBJECTIVE OF THE PROJECT
• Our objective is to make a lean implementation plan for any particular
organization which could be in manufacturing or service sector.

• For this purpose we have chosen SBI and presented a lean plan which can
be implemented in the organization.
LEAN PHILOSOPHY
• Lean manufacturing , often simply, "Lean," is a practice that considers the
expenditure of resources for any goal other than the creation of value for the
end customer to be wasteful, and thus a target for elimination.

• Lean manufacturing is a management philosophy derived mostly from

the Toyota Production System

• The term was first coined by John Krafcik in a Fall 1988 article, “ Triumph
of the Lean Production System”.

• Some of the goals of lean implementation is to improve quality, eliminate

waste, reduce time and reduce total cost.
LEAN TOOLS
• There are number of lean tools available but the tools which we have used
are:

• 5S
• KAIZEN
• KANBAN
• VSM
• TQM, and
• POKA YOKE
COMPANY PROFILE
• State Bank of India is the largest state owned banking and financial services
company in India.

• The bank has 131 overseas offices spread over 32 countries.

• SBI has 26,500 branches, including branches that belong to its associate
banks.

• The State Bank of India was founded by Sorabji Pochkhanwalain 1806 and
was previously known as Bank of Calcutta.

• The government of India nationalized the Bank in 1955.

5 S PHILOSOPHY
• Sorting (Seiri)

• Set in Order (Seiton)

• Shine (Seiso)

• Standardize (Seiketsu)

• Sustain ( Shitsuke)
SORTING
• The almirah and racks which is used to store files and all other stationeries
should be sorted according to the usage.

• One of the criteria may be Usage within a specific time frame.

• Files can be sorted according to the months.

• Each rack/almirah should be allotted a particular month and files belonging

to that month should be place only those racks/almirah.
SET IN ORDER
• All the files as well as racks/almirah should be labelled.

• Unnecessary files and other items should be send to the store room.

• A list should be made and pasted in a proper place which will tell about the
files store in the almirah and racks. This will make search easy and quick.

• Most frequently used files should be kept at levels which are easier to reach.
SHINE
• Rules should be made to regularly clean the almirah and racks where all the
files and other stationeries are stored.

• When used, files should be returned to their place from where they have
been picked up.

• Proper maintenance of file cover and office space should be done.

STANDARDIZE
• Standards should be set for a regular practice of 5s to be followed among
employees.

• For example: Labelling new file, putting them in the sequence of months,
and in the appropriate rack.

• The regular practice of 5s would make the organizations workspace cleaner

and more work friendly.

• Labeling of files and racks would reduce the time taken by an employee to
search for a particular file.
SUSTAIN
• The plan has to be followed strictly, regularly and by everyone right from
top to bottom.

• Everyone has to be oriented towards the consecutive benefits and how

important is everyone’s role in its implementation.

• The practices of labelling files and other plans should always be followed
and by everyone.

• This will result in sustaining the 5s plan by the organization which in turn
will result in cleaner and perfectly favourable working conditions.
KAIZEN
Kaizen focuses on continuous improvement of any process.

• This will first start with the process of standardizing an operation:

• Plan: teller will have stop watch on his table and he will press the button
after completing each request of the customer.

• Measure: the time a teller is taking will be measured by the stop watch.
KAIZEN
• Check: this time will be compared with the standard average time
established earlier.

• Act: action should be taken according to the results and if changes has to be
made it should be done immediately.

There should be a selected process that is on focus when dealing with kaizen
and the experts will have to provide a report that will give the details about
the facilitation of the actual kaizen event in the organization.
KANBAN
• It represents any visual method used to show the need for parts or products
to be moved or produced.

• This can be implemented in the organization by allotting separate boxes for

different forms with different colors.

• Forms which are available for ATM request, internet banking, for making
drafts etc. would be of different colors.

• There will be separate boxes for each forms and color of the box should
match the color of the form.
KANBAN
• So that form which is of red color would be dropped in the red color box.

• This will avoid mixing of forms and reduce the time taken for sorting each
forms.
POKA YOKE
• There are instances when people waiting in queue in front of the Teller,
break the queue or may be there are no queues sometimes. This hinders the
smooth working procedure.
• To prevent this problem barricades may be installed to maintain the queue.
▫ The barricade will have enough space for one person to pass easily.
▫ The barricade will direct the queue to the teller and then away.
▫ The exit of the barricade will be installed with a plank which opens in only one
direction.
▫ The people will only be able to exit through the EXIT.
TQM
Total Quality Management (TQM) programs in an attempt to retain or
regain competitiveness in order to achieve customer satisfaction.
VSM
• Value stream mapping is used to analyze the flow of materials and
information currently required to bring a product or service to a consumer.

• Follows a product or service from beginning to end.

• Provides a blue print for identifying and realizing quantifiable process

improvement opportunities.

• VSM can be used at various processes in a bank.

VSM
• Example: for sanctioning a loan it generally takes lot of time.

• VSM can significantly reduce the time taken for all the processes involved
in loan sanctioning.

• It will result in customer satisfaction as well as it will reduce the time taken
for any process.
CONCLUSION
• If the lean implementation plan given would be implemented, then it will
bring remarkable change in the office area.

• This plan is useful for all the service area of SBI.

• The plan would reduce the pain which an employee has to take for
searching a file if the area is not properly arranged.

• Will reduce the time taken for entertaining a particular customer.

CONCLUSION
• Everything will have its appropriate place and the office area would be
clearer.

• The lean implementation plan will increase the customer satisfaction level
of the SBI customers.

• This will lead to significant reduction in time taken in processes like loan
sanction, ATM issuing etc.

• Everyone will no their work and will do it with complete dedication as the
work area will be more work friendly after lean implementation plan.
•THANK YOU