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Lean System: - Presented By: - Siddhant Chavan - 14106A1003

The document discusses the Lean system, which was developed by Taiichi Ohno at Toyota after World War II. The Lean philosophy aims to provide perfect value to customers through a perfect value creation process with zero waste. It focuses on eliminating waste and empowering workers. Key elements of Lean include Just-in-Time (JIT) production, Kanban signals to communicate production needs, 5S organization, Jidoka for defect detection, Kaizen for continuous improvement, and Total Productive Maintenance (TPM). The goals of Lean are to reduce costs, inventory, production time and defects while improving quality, capacity and profits.

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Abhinandan Sawant
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91 views

Lean System: - Presented By: - Siddhant Chavan - 14106A1003

The document discusses the Lean system, which was developed by Taiichi Ohno at Toyota after World War II. The Lean philosophy aims to provide perfect value to customers through a perfect value creation process with zero waste. It focuses on eliminating waste and empowering workers. Key elements of Lean include Just-in-Time (JIT) production, Kanban signals to communicate production needs, 5S organization, Jidoka for defect detection, Kaizen for continuous improvement, and Total Productive Maintenance (TPM). The goals of Lean are to reduce costs, inventory, production time and defects while improving quality, capacity and profits.

Uploaded by

Abhinandan Sawant
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 14

LEAN SYSTEM

Presented By: Siddhant Chavan


14106A1003

January, 2016

INTRODUCTION
Engineer Taiichi Ohno. (After World War II.)
In simple terms, lean means creating more value
for customers with fewer resources.
The ultimate goal is to provide perfect value to the
customer through a perfect value creation process
that has zero waste.

PHILOSOPHY
Ohno vs. Ford
Ford - Maintaining resources in anticipation of
what might be required for future manufacturing.
Ohno - focus on eliminating waste and
empowering workers, reduced inventory and
improved productivity.

WASTE ELIMINATION

BASIC ELEMENT OF LEAN


JIT
Kanban
5Ss
Jidoka
Kaizan
TPM

JUST IN TIME
Concept - Activity should not take place unless
there is need for it.
Inventory should not be brought into the system
until it is required for making the final product.
Purchase raw materials JIT to be used for
production.
Produce & deliver finished goods JIT to be sold.

KANBAN
Designates a pull production means of communicating
need for product or service.
Means to communicate between operations in different
locations.

(Intended to communicate a change in demand or


supply)
Generally used to trigger the movement of material

to or though a process.

JIDOKA
Transferring human intelligence to semi-automated
or automated machinery.
Machines, not people detects production defects
and immediately stops themselves.
Such a stop is signaled via an ANDON signal.

5Ss

KAIZEN
Kai Change, Zen Good (for the better)
Continuous improvement - constantly introducing
small
incremental changes.
Everyday Everybody Everywhere Improvement
Existing operation
always has a room
for improvement.
10

RESISTANCE TO
IMPLEMENT KAIZEN

11

TPM
Total Overall operational efficiency of equipment
Total production system
Participation of all employees
Productive No defects
No breakdowns
No accidents
Maintenance Proactive & preventative maintenance

12

BENEFITS OF LEAN MFG.


1.

Waste reduction by
80%

2.

Reduction of
production cost by
50%

3.

4.

5.

production capacity increase

Reduction in
manufacturing cycle
time and labor
requirement by 50%

inventory reduction

Inventory reduction
by 80% maintaining
the same level of
customer service.

manufacturing cycle time reduction

Higher quality and


profits.

6.

Increase in capacity
by 50%

7.

More strategic focus.

labor reduction

production cost reduction


waste reduction
0 20 40 60 80100

14

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