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Overview of Lean-Management

The document discusses lean management principles including the seven types of waste, value adding vs non-value adding activities, benefits of lean management, and basic lean tools like 5S, Kaizen, and Poka-Yoke. It also outlines the stages of implementing lean management and provides examples of each lean concept.

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Karthik Manian
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192 views20 pages

Overview of Lean-Management

The document discusses lean management principles including the seven types of waste, value adding vs non-value adding activities, benefits of lean management, and basic lean tools like 5S, Kaizen, and Poka-Yoke. It also outlines the stages of implementing lean management and provides examples of each lean concept.

Uploaded by

Karthik Manian
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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CONTENTS
Lean Management Introduction Seven Types of Waste (in Lean) Value Adding (VA) & Non Value adding (NVA) activity Principles of Lean Management Benefits of Lean Management Implementation stages of Lean Management Process of Implementing Lean Management What are the Documents Basic Lean Tools & Principles 5S Kaizen Poka-Yoke

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LEAN MANAGEMENT INTRODUCTION


Lean is a philosophy that seeks to minimize the working capital required to produce a product or provide a service. Lean is all about eliminating all wastes & non-value adding activities from a process and making the product or service flow with reduced cost (working capital).
The concept of Lean in Manufacturing was developed by Henry Ford in 1920s

Toyota was the first company to introduce Lean Management concept in its production system.
Lean Management focuses on Eliminating / reducing

waste & Non-value adding activities.

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THE TOYOTA WAY OF LEAN


Zero inspection is a philosophy practised by

Toyota who are known for their world class performance and capabilities. They use Total Quality Management and Just-inTime (JIT) concepts. Suppliers are trained by their customers(Toyota) in quality management. Supplier quality becomes so reliable that their raw material can go straight to the customer's (Toyota) production line for immediate usage without the need for inspection and storage.

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SEVEN TYPES OF WASTE (in Lean)

TRANSPORTATION (excess travel due to poor layout) INVENTORY (Storage/Warehousing of excess materials)
MOTION (due to poor ergonomics of work station) WAITING (look for parts / waiting for parts/instructions)

OVERPRODUCTION (build more parts than required)

OVER-PROCESSING (Exceed customers requirement)

DEFECT FOR RE-WORK (Correction & Scrap same job again) UNDERUTILIZATION OF TALENT AND SKILLS
(is sometimes called the Eighth waste in Lean)

Value Adding (VA) ISPE, All Rights Reserved & Non Value Adding (NVA) Activity
Any Process Step/Activity which DIRECTLY adds

Value to the final output (product/service) produced by the process, such process step/activity is First Time Right (FTR) & for which (process step/activity) the customer is WILLING to pay is called as Value Adding (VA) Activity Any Process Step/Activity which does NOT add value Directly to the final output (product/service) produced by the process & where the customer is NOT willing to pay for such Step/Activity is called as Non Value Adding (NVA) Activity

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PRINCIPLES OF LEAN MANAGEMENT


To create continuous flow
To use pull-systems to manage the workflow To eliminate/reduce batch sizes and inventories

To eliminate waste
To cross-train workers in order to deal with inherent variability

Selective use of automation (ie, autonomation)


To instill a Continuous Improvement competence

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BENEFITS OF LEAN MANAGEMENT


Improves process flow/speed
Productivity Improvement Total manufacturing time saved

Less scrap
Low inventory Plant space saved

Better labor utilization


Reduce cost (working capital) Safety of operations

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IMPLEMENTATION STAGES OF LEAN MANAGEMENT


Three stages in the implementation of Lean Management are:
Data collection stage Data analysis and Development of

solution Stage Implementation Stage

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PROCESS OF IMPLEMENTING LEAN MANAGEMENT

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WHAT ARE THE DOCUMENTS ??

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BASIC LEAN TOOLS & PRINCIPLES

5S

KAIZEN
POKA-YOKE

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5S
The 5Ss are: SORT Clear distinction of needed items from unneeded ones & eliminating the latter. STRAIGHTEN / STABILIZE / SET-IN-ORDER Keeping needed items in correct place to allow for easy and immediate retrieval. SHINE Keeping the work area clean. STANDARDIZE Developing work processes to support the first three steps. SUSTAIN Putting processes in place to ensure that the first four steps are rigorously followed.

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KAIZEN
It is a Japanese word that means to break

apart or Modify (Kai) to make things Better (Zen). It focusses on eliminating the wastes in a process so that the processes only add value to the customer. Some of the seven wastes targeted by Kaizen are Waiting / Idle time / Search time, Correction, Transportation, OverProduction, Over-Processing, Excess Motion, Storage / Warehousing.

KAIZEN WORK SETUP AT PHILLIPS

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POKA-YOKE
Poka -Yoke is a structured methodology for mistake proofing operations. It is any device or mechanism that either prevents a mistake from being made or ensures that the mistakes dont get translated into errors that the customers see or experience.

There are three approaches to Poka Yoke: Warning (making the user aware of the potential problem) Control (Auto change to counteract (in case of) problem) Shutdown (Auto closure to prevent damage in case of error)

POKA-YOKE EXAMPLE NEW ATM MACHINES PREVENT WE FORGETTING CARD IN IT

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Thank You

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