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Lean Manufacturing: Waste Elimination Guide

Lean manufacturing aims to eliminate waste and optimize efficiency. It is built upon two pillars: just-in-time (JIT) production and jidoka, which means automation with a human touch. Jidoka aims to stop production lines when defects are detected to prevent defective products from advancing. Implementing lean manufacturing requires significant cultural change, like being willing to stop lines when defects occur. The goals of lean manufacturing are cost reduction by eliminating waste, ensuring product quality, and creating a workplace that considers operators. It works to classify and remove seven types of waste from production processes.

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40 views11 pages

Lean Manufacturing: Waste Elimination Guide

Lean manufacturing aims to eliminate waste and optimize efficiency. It is built upon two pillars: just-in-time (JIT) production and jidoka, which means automation with a human touch. Jidoka aims to stop production lines when defects are detected to prevent defective products from advancing. Implementing lean manufacturing requires significant cultural change, like being willing to stop lines when defects occur. The goals of lean manufacturing are cost reduction by eliminating waste, ensuring product quality, and creating a workplace that considers operators. It works to classify and remove seven types of waste from production processes.

Uploaded by

amolbagade
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd

Lean Manufacturing

Definition
Lean manufacturing is the implementation of the
concept that anything that does not create value in
the product is to be eliminated. It is the concept of
more value for less work.
In simple words : Lean is a system of cost reduction
focusing on the elimination of waste .
OR
A systematic approach to identifying and eliminating
waste(non-value-added activities) through continuous
improvement by flowing the product at the pull of the
customer in pursuit of perfection.

TWO PILLER
It is built upon two pillars:
JIT and
Jidoka

JIT :- Just in time


Jidoka :- The term jidoka used in the TPS (Toyota
Production System) can be defined as "automation
with a human touch."
The Toyota term "jido" is applied to a machine with a built-in
device for making judgments, whereas the regular Japanese
term "jido" (automation) is simply applied to a machine that
moves on its own. Jidoka refers to "automation with a human
touch," as opposed to a machine that simply moves under
the monitoring and supervision of an operator.

JIDOKA

One principle of Jidoka is that no defective parts


should advance in the production system.
In a simple word; when we do have a defect, we
will need to shut down the line until the problem is
solved and were assured no defective product can
go forward

Need Cultural Change


Cultural Change Sometimes Seems Impossible
Ex. Shutting down line for each defective prod.
Example of two-month-old son to play soccer
First, he must crawl, then he must walk, then when he is
into running, there is some hope of teaching him soccer
before that, it is not a reasonable goal

Like the same way, The production plant must first


learn to crawlit must have a product to sell, must
have good leadership, good problem solvers, and a
willingness to change. Only then can it walk and
develop a solid quality system with high levels of
product stability, good process stability, and a deep
understanding of variation.

The Goals of Lean


Manufacturing
Cost Reduction by Elimination of Waste
Creating Conditions to Guarantee Product
Quality
Creating a Work Site with Operators in
Mind

Cost Reduction by Elimination of


Waste
A functional classification of the various elements
that only raise cost in production activity gives
the following seven types of waste:

Waste
Waste
Waste
Waste
Waste
Waste
Waste

of defect repair
of overproduction
of waiting
in delivery and conveyance
in processing
of inventory
of motion

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