Lean Tools application with powerpoint animation. all processes are easily described with images & animation.
Uploaded by
Ishmam Ahmed
Industrial & Production Engineering (IPE)
Shahjalal university of science & Technology, Sylhet, Bangladesh
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Applications of lean manufacturing tools
1. WELCOME TO THE PRESENTATION
ON
APPLICATIONS OF
LEAN APPROACH
IN
MANUFACTURING
2. COURSE NAME: Business Communication Seminar
COURSE NO: IPE-326
PRESENTED BY
MEMBER’S NAME REG NO:
Ismam Ahmed 2012334062
Musaddeque Hossain 2012334063
Reduan Islam Hridoy 2012334065
Sabbir Ahmed 2012334064
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
SHAHJALAL UNIVERSITY OF SCIENCE &TECHNOLOGY, SYLHET
3. CONTENTS What is lean?
Component of lean manufacturing
7 types of wastes
Origin of lean
5S
Batch size reduction
Kanban
Kaizan
Visual contents(Andon,Footprint,Signage)
Cellular plant
Lean in Bangladesh
1
4. It is a comprehensive set of techniques that are
used to identification and stady elimination of
wastes,improvement of quality,reduction of
production and cost
What is lean
Elimination of waste
Improve of quality
Identification
Reduction cost
2
5. TPS Definitions of Waste(7 types)
1. Overproduction
2. Waiting, including time in
queue
3. Transportation (between
workstations, or between
supplier and customer)
4. Non-value-adding activities
5. Inventory
6. Waste motion
7. Cost of poor quality: scrap,
rework, and inspection
“Anything that adds Cost to the product without adding Value”
3
6. Team work
Origin of Lean
Statiscal Process
Control
Plan-Do-Check-Act
cycle
Assembly
line
StandardizedWork
Timestudy
Interchangeable parts
Work
Division
“Doing more with
less”
JIT
Jidoka
Kaizen
SMED
Pull system
4
7. Waste is Often Built Into Jobs
Gilbreth study on brick setup
Need 7-8 sec to setup a single brick Need 2-3 sec to setup a single brick
5
15. 5S (Workplace Organization)
Organisation/
Sort out
SEIRI
Orderliness/
Systemize
SEITON
Standardize
SEIKETSU
Sustain/
Discipline
SHITSUKE
The Cleaning/
Shining
SEISO
Developed by the Japanese
Housekeeping System
Helps Create a Better Working Environment and a Consistently High Quality Process
Make faster assembly plant
13
16. 5S Effect on Office
Clean top
Similar
papers in
files
Paper
arranged
SEIRI SEITON SEISO SEIKETSU SHITSUKE
14
18. Types of Andon
Coded signal lightsText Graphics
Visual Andon
Green - no problems
Yellow - situation requires
attention, production flow at risk
Red - PRODUCTION STOPPAGE:
IMMEDIATE ASSISTANCE
REQUIRED
1
Display production data in
real time.
Calculate shift efficiencies
and production targets.
Ideal for STOP /
WAIT / GO signaling
in busy factories
Boost health and
safety.
Coded
Tones
Coded
Tunes
Prerecorded
Messages
Buzzers
/ Alarms
Audio Andon
2
ANDON
16
19. FOOT-PRINT
avoids employees wasting time looking for things
The workplace becomes clean and better organized.
Operation on the shop floor and office become easier and safer
Use colours as a guideline :
Light Blue - Raw parts/material
Black - Finished good/parts
Red - Non-conforming/KIV parts/material
White - Other than parts/material
Yellow – Border of work area
17
21. KAIZEN
ACT
Check
Do
Plan
Customar
Need
Kaizen
• is a tool to rapidly improve work as part of the PDCA cycle
• is a tool for Continuos process
• goals must align with the business objectives
KAI ZEN = Change for the better
19
22. Cellular Layout
• Produces families of parts within a single line
• Reduce cycle time
• Reduce time wastes
Storage
Drilling
joint
Threading Turning
Packing
Data
45
%
65
%
Assembly
check
Quality
20
24. Reduction in unit production cost
Company Name Before
Lean
($)
After
Lean
($)
Reduction
($)
As a %
1. Fashion Point Ltd.
2. Texas Fashion Ltd.
3. Beximco Fashions Ltd.
4. Shanta Industries Ltd.
5. DADA (Savar) Ltd.
6. Shata WashWorks Ltd.
7. Armana Fashions Ltd.
8. Shanta Denims Ltd.
9. PAXAR Bangladesh Ltd.
8.50
11.0
4.40
10.0
1.40
3.50
0.87
-
4.50
7.00
9.00
3.20
8.00
1.30
3.00
0.84
-
3.00
1.50
2.00
1.20
2.00
0.10
0.50
0.03
-
1.50
17.6
18.1
27.2
20.0
7.1
14.2
3.4
-
33.3
Application of lean in Bangladeshi companies
22
25. Removes unnecessary activities
Removes in-plant inventory
Removes in-transit inventory
Improves quality and reliability
JUST IN TIME (JIT)
23
26. Traditional approach
JIT approach
stage A
orders
deliveries
orders
deliveries
JIT material flow
buffer
inventory
stage B
buffer
inventory
stage
C
stage A stage Cstage B
24
27. POKA-YOKE(ERROR PROOF)
POKA-YOKE is part of the Just-in-time philosophy
POKA-YOKE reduces the defect rate that is part of the OEE rate
Weight
Dimensions
Shape
Suggested Methods:
25
Hello everyone
I am ishmam ahmed
My registration number is 2012334062
The topic of our presentation is “application of lean approach in manufacturing
Our group consists of four members
Here is the contents of our presentation
Basically it contains about lean, lean tools and their applications
Hope it will make a clear understanding about “Lean Processing”
If Jidoka is not practiced then you can not attain a very high level quality and productivity will suffer since you are not catching problems.”
Mr. Tomo Harada, 35 years with Toyota Motor Corporation in a variety of management positions