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Presentation - Lean Manufacturing Techniques - Lecture 04

The document discusses lean manufacturing techniques including value stream mapping, production smoothing concepts, just-in-time production and Kanban systems, single-piece flow, single minute exchange of dies, process visualization, standard work, and A3 thinking for problem solving. It provides details on conducting a Gemba walk and 12 steps to ensure it is done properly. It also discusses line balancing and the concepts of pull vs push in manufacturing.

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Nadun Nilupul
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134 views13 pages

Presentation - Lean Manufacturing Techniques - Lecture 04

The document discusses lean manufacturing techniques including value stream mapping, production smoothing concepts, just-in-time production and Kanban systems, single-piece flow, single minute exchange of dies, process visualization, standard work, and A3 thinking for problem solving. It provides details on conducting a Gemba walk and 12 steps to ensure it is done properly. It also discusses line balancing and the concepts of pull vs push in manufacturing.

Uploaded by

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

PR517 LEAN MANUFACTURING

LEAN MANUFACTURING TECHNIQUES – LECTURE 4


DR . R . A .EK ANAYAK E
DE PA RTMENT OF M A N U FAC TU RING A N D I N DU STRI AL E N GI NEER ING
Refe ren ce – Le a n i n Pra ct ice by Le a n S i x S i gma Comp a ny
Recap:
Creating the VSM – current state map
• Collect the data and information by "walking the flow" (i.e., Gemba walks) and
interviewing the people who perform the task.

• Gather information including


Cycle time or processing time Changeover time
Reliability of equipment First pass yield
Quantities Number of operators and shifts
Hard copy information Electronic information
Inventory levels Queue or waiting times
GEMBA
OBSERVE
COMMUNICATE

RECOGNIZE

COOPERATE SOLVE THE


PROBLEM

WALK
12 Steps to GEMBA Walk

1 Inform site or department in advance that you will be visiting and carrying
out a GEMBA walk.

2 Respect the site or department work process and arrive at an agreed time in
the required Personal Protective Equipment (PPE).

3 Introduce your self and set context to the visit


12 Steps to GEMBA Walk

4 Let it be known that you will share your thoughts and observations
afterwards.

5 Be thoughtful about group size.

6 Request the process owner to accompany you on your walk.


12 Steps to GEMBA Walk

7 Take a walk through the core activities of the whole , extended enterprise.

8 Ask open-ended questions.

9 Listen.
12 Steps to GEMBA Walk

10 Be discreet with the observation sheet , e.g ask permission to make notes.

11 Encourage the site or office to provide their honest feedback on the GEMBA
walk and how it was conducted.

12 Review and follow up on your notes. Resolve any problems identified , and
inform respective management of both the follow-up action taken and the
resolution.
Group Presentations
Section 3 - Lean Manufacturing Techniques
– Value Stream Mapping
– Production smoothing concepts
– Just in Time Production (JIT), Kanban systems
– Single piece flow concept
– Single Minute Exchange of Dies (SMED)
– Process visualization
– Standard Work
– A3 Thinking for Problem Solving
Line Balancing – Yamazumi

Step -01
The work in progress is 40 quotations, the back office makes 4 quotations per day. How long does
the customer have to wait for the quotation? What is the Process Lead Time (PLT)of this process?

Answer:
PLT = WIP / Exit Rate,
PLT = 40/4 (per day) = 10 days
Pull

•Downstream pull whatever they need based on their consumption from the upstream
•Upstream do not produce any thing without the request from down stream (Customer Demand)
•Minimum and control inventory (good inventory)
Push

•Up stream push whatever they produce to the downstream customer process
•Do not consider about the demand of downstream customer
•Build inventories (Bad Inventory) / No inventories

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