Lean PPT

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What is Lean Manufacturing?
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Table of Contents

• What is Lean Manufacturing.
• Where it Comes From
• Who Invented It
• Purpose of Lean
• How Lean Manufacturing Works
• 5 Principles of Lean Manufacturing
• Lean Tools and Concepts
• How Can it Be Implemented
• Challenges and Solutions in Lean Implementation
• Future of Lean Manufacturing
• Conclusion

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Introduction
Lean Manufacturing is a systematic approach to
minimizing waste within a manufacturing system
without sacrificing productivity. It
emphasizes efficiency, quality, and customer
value, shaping the competitive landscape of the
manufacturing industry. Lean production is a
robust worldwide methodology that enhances
operational efficiency and competitiveness.
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What is Lean Manufacturing?
Lean Manufacturing is a methodology that focuses
on reducing waste and improving manufacturing
processes. It aims to create more value for
customers with fewer resources by optimizing
production flow and eliminating inefficiencies.
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Where It Comes From
The roots of Lean Manufacturing can be traced
back to the post-World War II era in Japan.
Toyota Motor Corporation, led by Taiichi Ohno and
Eiji Toyoda, developed the Toyota Production
System (TPS), emphasizing efficiency and waste
reduction. TPS became the foundation of Lean
Manufacturing, influencing countless industries
beyond automotive production. This historical
context is crucial to understanding how Lean
Manufacturing principles were formulated and
refined over decades.

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Who Invented Lean Manufacturing
Lean Manufacturing was developed by Toyota
engineers Taiichi Ohno and Eiji Toyoda, evolving
from the Toyota Production System (TPS). The
term "Lean" was popularized by James Womack,
Daniel Jones, and Daniel Roos in their 1990 book
"The Machine That Changed the World."
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Purpose of Lean Manufacturing
The primary purpose of Lean Manufacturing is to
enhance customer value by systematically
eliminating waste. Lean principles aim to
streamline production processes, improve product
quality, reduce lead times, and lower costs.
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How Lean Manufacturing Works
Lean Manufacturing identifies and eliminates
waste in all formsoverproduction, waiting,
transportation, overprocessing, excess inventory,
unnecessary motion, defects, and underutilized
talent. It relies on continuous improvement,
where small, incremental changes are made
regularly to enhance efficiency and
effectiveness.
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5 Principles of Lean Manufacturing

1. Value Define what is valuable to the customer
   and focus on it. Understanding customer needs and
   preferences is crucial for identifying value.
2. Value Stream Map out all steps in the value
   stream and eliminate non-value-added steps. This
   helps visualize the entire process and identify
   areas for improvement.
3. Flow Ensure the product flows smoothly through
   the production process without delays. Creating a
   smooth flow reduces bottlenecks and
   inefficiencies, ensuring that each step in the
   process is optimally aligned.
4. Pull Produce only what is needed when needed in
   response to customer demand.
5. Perfection Continuously strive for perfection by
   identifying and removing the root causes of
   problems.

1. Value Define what is valuable to the customer
   and focus on it. Understanding customer needs and
   preferences is crucial for identifying value.
2. Value Stream Map out all steps in the value
   stream and eliminate non-value-added steps. This
   helps visualize the entire process and identify
   areas for improvement.
3. Flow Ensure the product flows smoothly through
   the production process without delays. Creating a
   smooth flow reduces bottlenecks and
   inefficiencies, ensuring that each step in the
   process is optimally aligned.
4. Pull Produce only what is needed when needed in
   response to customer demand.
5. Perfection Continuously strive for perfection by
   identifying and removing the root causes of
   problems.

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5 Process Flow of Lean Manufacturing Principles
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8 Wastes of Lean Manufacturing

• Overproduction
• Waiting
• Transportation
• Overprocessing
• Inventory
• Motion
• Defects
• Underutilized Talent

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Lean Tools and Concepts

• 5S Sort, Set in order, Shine, Standardize,
  Sustain. This tool enhances workplace
  organization by creating a clean, orderly, safe
  work environment.
• Kaizen Continuous improvement. It encourages
  small, incremental changes to improve processes
  continually, fostering a culture of ongoing
  enhancement.
• Kanban Visual scheduling system. It helps manage
  workflow and improve efficiency by ensuring work
  is pulled through the production process as
  needed, reducing bottlenecks.
• Value Stream Mapping Visual tool to analyze
  current, future states of processes. It helps
  identify waste and opportunities for improvement
  by mapping out the entire production process.
• Just-In-Time (JIT) Producing only what is needed
  when it is required. JIT helps reduce inventory
  costs and increase efficiency

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Complete list of Lean Tools and Concepts
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How Can it Be Implemented

• Implementing Lean Manufacturing involves several
  steps
• Assessment
• Training
• Pilot Projects
• Full Implementation
• Continuous Improvement

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Challenges in Lean
Implementation
1. Resistance to Change Employees may resist new
ways of working. Change can be difficult, and
addressing concerns and involving employees in
the process is essential. 2. Insufficient
Training Lack of understanding of Lean
principles. Proper training is crucial for
successful implementation. Providing
comprehensive training programs can help build
Lean capabilities. 3. Inconsistent Application
Consistency is critical to achieving long-term
success with Lean Manufacturing. Developing
standard procedures and ensuring adherence to
Lean practices can help maintain consistency.
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Solutions in Lean Implementation
1. Comprehensive Training Provide ongoing
education on Lean tools and concepts. Continuous
training helps ensure that everyone can apply
Lean principles effectively. 2.
Standardization Develop standard procedures to
maintain consistency. Standardization helps
ensure that Lean practices are applied
consistently across the organization. 3.
Long-term Perspective Focus on sustainable,
long-term improvements. Maintaining a long-term
perspective helps ensure that Lean Manufacturing
delivers lasting benefits.
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Future of Lean Manufacturing

• Lean Manufacturing will also increasingly focus
  on sustainability, addressing environmental
  concerns by reducing waste and energy
  consumption.
• The circular economy concept, which emphasizes
  resource efficiency and waste minimization,
  aligns well with Lean principles and will shape
  the future of Lean Manufacturing. As
  organizations strive to reduce their
  environmental footprint, Lean practices will be
  critical in achieving sustainability goals.
• Additionally, the rise of Industry 4.0,
  characterized by smart factories and
  interconnected systems, will further enhance the
  capabilities of Lean Manufacturing.

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Recap of Key Points

• Lean Manufacturing is about minimizing waste and
  maximizing value.
• Originated from Toyota's Production System. -
  Focuses on continuous improvement and efficiency.
  
• Involves principles like value, flow, pull, and
  perfection.
• Applicable across various industries for
  sustainable growth and success.

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BENEFITS OF TQM

• Increased Efficiency
• Improved Quality
• Cost Reduction
• Enhanced Flexibility
• Employee Engagement
• Customer Satisfaction

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Importance of Lean in Manufacturing Industry
Lean Manufacturing is crucial in the
manufacturing industry as it enhances efficiency,
reduces waste, and improves product quality. By
streamlining processes and emphasizing continuous
improvement, Lean helps companies respond quickly
to market demands, reduce costs, and maintain a
competitive edge in a rapidly evolving market.
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Advantages of tqm

• Enhanced Efficiency Streamlined processes and
  waste reduction accelerate production.
• Higher Quality Continuous improvement practices
  lead to better product quality.
• Cost Savings Reduced inventory and optimized
  resources lower operational expenses.

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Disadvantages of tqm

• Employee Stress Continuous pressure to improve
  and eliminate waste can lead to high stress and
  burnout among workers.
• Supply Chain Vulnerability Lean's minimal
  inventory approach can cause disruptions if
  supply chain issues arise.

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Models of Lean Production
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BENEFITS OF APPLY LEAN IN MANUFACTURING INDUSTRY

• Increased Efficiency Lean reduces waste,
  streamlines processes, and improves workflow,
  leading to faster production times.
• Improved Quality Emphasis on continuous
  improvement and defect prevention enhances
  product quality.
• Cost Reduction Lower inventory levels and
  optimized resource use significantly cut
  operational costs.

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CONCLUSION
Lean Manufacturing implementation remains a
pivotal strategy in modern production, focusing
on waste reduction and value creation.
Organizations can significantly enhance their
efficiency and competitiveness by understanding
their principles, tools, and implementation
strategies. Lean Manufacturing is a set of
tools and a comprehensive philosophy guiding
continuous improvement and operational excellence.
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