The Complete Presentation on Lean Manufacturing.

1. Presented By,
Amar M. Borkute

2. The core idea of lean manufacturing is actually quite simple…relentlessly
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 customer’s perspective.
 According to research conducted by the Lean Enterprise Research Centre (LERC), fully
60% of production activities in a typical manufacturing operation are waste – they add
no value at all for the customer.
 The good news is that just about every company has a tremendous opportunity to
improve, using lean manufacturing techniques. Techniques that enable you to deliver
higher quality products at significantly lower costs.
Now that is something to get excited about!

3.  Ford put many ideas together when he first designed his production line for the model T
Ford, however he did not invent very much of it himself. The ideas of having interchangeable
parts and the like were not new to Ford, they had been around for a long time, the principles
had been used by Eli Whitney to manufacture muskets at the end of the 18th Century.
 Fredrick Taylor’s work on scientific management investigated workplace efficiencies and
Frank Gilbreth looked at motion studies. Both of their works influenced the design and
functioning of the Ford production lines.
 Fords methods however worked for mass production and were highly effective during world
war II where Ford helped to build Bombers at the Ford Willow Run plant and Boeing.
Origin of Lean Manufacturing

4.  After world war II the US helped Japan rebuild its manufacturing capability, they did this by
sending a number of “consultants” to provide aid and advice. The people that they sent were
people like Deming who had no success at getting the Americans to listen to his philosophy
with regard to Quality and Management. The Japanese however listened and learned.
 Through Deming, Juran, Shewhart and the other consultants that were bought into help them
Toyota and the other Japanese companies learned the importance of quality and satisfying
their customers. Toyota also listened and developed the concept of Just in Time (JIT),
together with Jidoka this formed the two main pillars of the fledgling Toyota Production
System (TPS).
Development of the Toyota Production System

5. Lean Manufacturing Goals

6. 5 S
Value Stream Mapping
Cellular Manufacturing
KAIZEN
Visual Management
Lean
Manufacturing
Tools

8. KAIZEN Process

9. Visual Management

10. Cellular Manufacturing
Cellular manufacturing is a process of manufacturing which is a subsection of just-in-
time manufacturing and lean manufacturing encompassing group technology. The goal
of cellular manufacturing is to move as quickly as possible, make a wide variety of
similar products, while making as little waste as possible.
 Improved material flow
 Reduced queuing time
 Reduced inventory
 Improved use of space
 Improved team work
 Reduced waste
 Increased flexibility Functional layout
Cellular layout

11. © Siemens Power Generation Systems
Functional layout

12. Manufacturing cells
© Siemens Power Generation Systems

13. Multifunction double gantry mill
© Siemens Power Generation Systems
A single machine acting as a cell

14. Value stream mapping is a lean-management method for analyzing the current state and designing
a future state for the series of events that take a product or service from its beginning through to the
customer. At Toyota, it is known as "material and information flow mapping".
Value Stream Mapping