1. Operations Management-II Dr. S.Venkataramanaiah Assistant Professor OM & QT Area IIM Indore, Pigdamber, Rau Indore- 453 331 Email : [email_address]

2. Lean Manufacturing

3. Lean Manufacturing Implementation Source : Mr. D.S. Viswanath, AVTEC Indore

7. What is Lean Manufacturing ? MORE LESS INVENTORY MORE LESS LEAD TIME MORE LESS SPACE MORE LESS DEFECTS MORE LESS HUMAN EFFORT MORE LESS BREAK DOWN MORE LESS FOLLOW-UP MORE LESS COST LEAN MEANS LESS LESS = JUST NEEDED

11. Lean Production in Factory Management Lean Factory Management Process design Planning & Process Control Techniques Support Routines Analytical Tools & techniques Behavioral & Organizational Underpinnings

12. Process Design Product flow Multi-Process/ Multi-Machine Handling Pokayoke - quality at source Value - Added work One - Part Processing through sequential Operations Processing Through Sequential Operations work Place / Work Cell Arrangements Quick Set-Ups Miscellaneous Support elements Process Design for Lean Manufacturing

14. CHANGE FORM OR QUALITY WORK MACHINING ASSEMBLY ETC TRANSPORT (MOVEMENT STORAGE) INSPECTION ETC VALUE ADDED WORK ONLY ADDS COST WASTE YES NO Value Added Work

15. Implementation- An Example

17. 1. FACING & CENTERING M/C (NEW) 9. THREAD ROLLING-MTR 15 17. GEAREDMOTOR TABLE 2. STC 25 – II 10. HF1 MILLING M/C 18. AWH GRINDER MKL 3. CNC LATHE STC 20 11. FN 2 EH MILLING M/C 19. K 130 P GRINDER 4. AXLE HOLE SPM –TAURUS 12. HF 1 EH MILLING M/C 20. K 30 P GRINDER 5. FN 3 H MILLING M/C 13. FN 2 EH MILLINGM/C 21. FN 2 EH MILLING M/C 6. FELLOWS – RECONDITIONED 14. INDUCTION HARDENING M/C PILLAR 22. SUB ASSEMBLY TABLE 7. HOBBING M/C PSG 15. TEMPERING FURNACE PYROMASTER 23. INDUCTION RIVETTING M/C 8. TEETH CHAMFERING M/C UBIQUE 16. MAGNAFIELD CRACK DETECTER 2 3 18 19 20 1 16 8 7 11 10 17 21 9 4 13 12 5 6 23 22 14 15

22. More Space SPACE FOR MACHINE SPACE FOR STORING INCOMING & OUTGOING COMPONENTS TROLLEY SPACE FOR TROLLEY’S MOVEMENT-WIDER AISLES MORE SPACE MACHINE INCOMING TROLLEY OUTGOING TROLLEY MOVEMENT MOVEMENT

23. More Defects 1 2 3 4 5 6 7 8 Defect produced in taper dia. angle Defect in taper dia. angle affects serration & visibly seen at this stage TIME ELAPSED 950 MINUTES (COMPONENTS PRODUCED – 230) HENCE MORE (230) DEFECTS !

35. Less defects (components produced – 5/6 ) Hence less (5/6) defects ! Since communication is faster, remedial action is immediate this will enable ZERO DEFECT 1 2 3 4 5 6 7 8 Defect produced in taper dia. angle Defect in taper dia. angle affects serration & visibly seen at this stage time elapsed 35 minutes