Lean production and methods

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Lean production and methods
Prepared by Stefanie Kirchner
University of Economics - Varna
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Lean production and methods

• Overview of lean production
• Benefits of lean production
• Kaizen
• Just-in-time / Just-in-sequence
• Jidoka
• Kanban
• Heijunka
• Poka-Yoke
• 5 S

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What is Lean production?

• less time, inventory, space, labor, and money
• eliminating waste, simplifying procedures and
  speeding up production.
• also known as Toyota Production System
• Toyota was able to greatly reduce leadtime and
  cost using the TPS (Toyota Production System),
  while improving quality at the same time

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What is Lean production?

• systematic elimination of the 7 types of waste
• Overproduction
• Waiting
• Transportation
• Inventory
• Motion
• over-processing,
• defective products
• The japanese call it Muda ?? (engl.waste)

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Benefits from Lean production

• Waste reduction by 80
• Production cost reduction by 50
• Manufacturing cycle times decreased by 50
• Labor reduction by 50 while maintaining or
  increasing throughput
• Inventory reduction by 80 while increasing
  customer service levels

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Benefits from Lean production

• Capacity in current facilities increase by 50
• Higher quality
• Higher profits
• Higher system flexibility in reacting to
  changes in requirements improved
• More strategic focus
• Improved cash flow through increasing shipping
  and billing frequencies

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Kaizen ??

• philosophy of continual improvement
• involving everyone managers and workers
• Management has two major components
• maintenance, and
• improvement

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Poka-Yoke ????

• defect warning system
• make it impossible to make mistakes
• initial term was baka-yoke, which means
  fool-proofing
• improve quality and reliability
• can eliminate both human and mechanical errors

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Kanban card
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Kanban ??

• to achieve Just-in-time
• pulls just the number and type of components the
  process requires
• physical card or other devices

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Jidoka???

• meaning automation with a human touch
• quality control process
• four principles
• Detect the abnormality
• Stop
• Fix or correct the immediate condition
• Investigate the root cause and install a
  countermeasure

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Jidoka???

• Jidoka involves the automatic detection of errors
  or defects during production
• helps to detect a problem earlier and avoids the
  spread of bad practices

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• Thank you for your attention!