Chapter - 1 Introduction To Lean Manufacturing

Lean
Operations
Definition
It is a comprehensive set of
techniques that, when combined
and matured, will allow you to
reduce and then eliminate the
seven wastes.
Definition - 2
• Lean production is a systematic
manufacturing method used for eliminating
waste within the manufacturing system. It
takes into account the waste generated from
uneven workloads and overburden and then
reduces them in order to increase value and
reduce costs. The word ”lean” in the term
simply means no excess, so lean production
can be translated simply into minimal waste
manufacturing.
Lean Manufacturing
• “Lean is a system of cost reduction focusing

on the elimination of waste. It is built upon
two pillars: JIT and Jidoka.”
• JIT stands for Just In Time
• Jidoka is a way to use machines and
manpower more effectively and to show
respect for people.
What is Jidoka & Poka yoke
- One principle of Jidoka is that no defective parts
should advance in the production system. (kanban)
Get everyone involved in problem solving. (Poka yoke ).
And when we do have a defect, we will need to shut
down the line until the problem is solved and we’re
assured no defective product can go forward.”
But for this we need a cultural change in the
organization and implement :
“Involvement and Empowerment.”
What is Employee Involvement?
• It’s a way of engaging employees at all
levels in the thinking process of an
organization.
• It’s the recognition that many decisions
can be made better by seeking the input of
those who may be affected by them
• It’s an understanding that people at all
levels in an organization possess unique
talents, skills and creativity that can be of
significant value if allowed to be expressed
What is empowerment?
• Empowerment is not something “nice” we do
for our employees to make them feel better.
• It’s an understanding that it’s everyone’s
obligation – part of the job- to constantly
look for better ways of doing things.
• It’s part of the job to ask questions and raise
issues of concern, to get them out on the table
so they can be resolved.
• It’s a major change of direction in the way
we lead our workforce.
What is empowerment? (Cont….)
• It’s a change that affects the culture of the
workplace as we know it.
• Empowerment is employee involvement in a way
that matters.
• It is the controlled transfer of authority to make
decisions and take actions
• The difference between involvement and
empowerment is, just having input and having
input that is heard, considered and allowed to be
implemented.
Therefore it’s a change that must be
implemented with great care and attention.
Empowerment Requires a
change in Culture
• Successful implementation or empowerment
requires change in corporate culture
• It’s a major new direction in how managers
think and work
• The division of work between managers and
workers changes with empowerment
Empowerment & Participatory
Management
• Participatory Management is about managers
asking for employee’s help in problem solving and
decision making.
• Empowerment is about getting employees to help
themselves, their teammates and the company.
• Empowerment helps employees develop a sense of
ownership of their jobs and of the company.
• Empowerment leads to greater willingness to
make decisions, take risks in an effort to improve
and speak out when they disagree.
Tools of Empowerment
• Suggestion Boxes
• Brainstorming
• Nominal Group Techniques
• Quality circles
• Walking & Talking
Suggestion system
• Establish suggestion Policy
• Set up suggestion system
• Promote suggestion system
• Evaluate suggestions
• Implement suggestions
• Reward employees for suggestions
• Review & Improve suggestion system
Handling Poor Suggestions
• Listen carefully
• Express appreciation
• Carefully explain your position
• Encourage feed back
• Look for compromise
Empowerment Traps
• Defining empowerment as Discretion and
self reliance
• Failing to define the new roles of
supervisors and managers
• Assuming employees have the skills to be
empowered
• Getting impatient
Benefits of Empowerment
• Reduced Absenteeism
• Reduced Turnover
• Better Work Safety
• Improved Quality
• Better Sense of Feeling
• Industrial Reputation
Empowerment
a motivational technique
• Empowerment is the key to motivation and
productivity. An employee who feels he is valued
and can contribute is ready to help and grow in
the job.
• Empowerment enables a person to develop
personally and professionally so that his
contributions in the workplace are maximized.
Obstacles to Empowerment
• Resistance from employees
– Skepticism due to past experiences
– Inertia to change
– Fear of learning and training
– Assumptions about higher expectations
• Resistance from unions
– Adversarial relationship between organized
labor and management
– Resentment towards an idea not originated by
the union
– Concern about affects of empowerment towards
their future
• Resistance from Managers
– Insecurity
– Personal values
– Ego
– Management training
– Personality characteristics
– Exclusion of managers
Management’s Role
in Empowerment
• Exhibiting a supportive attitude
• Being a role model
• Being a trainer
• Being a facilitator
• Practicing MBWA
• Taking quick actions on recommendations
• Recognizing the efforts of employees

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Lean

• “Lean is a system of cost reduction focusing

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