Lean Manufacturing
Overview
Objective . . .
Definition of Lean
Manufacturing
Importance of Lean
Manufacturing
8 forms of
Manufacturing Waste
Different tools in Lean
Manufacturing
How do we make the
right product on time?
How do we grow?
How do we lower our
stock room inventory ?
How do we maintain a
good quality product ?
Could we hire more people
and buy more machines?
Could we increase the price
of our product?
Goals . . .
 Produce more product using the current resources.
 Lower the stock room inventory.
 Accurate forecast on how long it takes to make the products
and ship them on time.
 Get all the needed parts for Assembly at the right time.
What is LEAN ?
A systematic approach to identifying and eliminating waste through
continuous improvement in pursuit of perfection.
Striving to do more with less, and do it
consistently.
Work Smarter Not Harder
The LEAN Formula. . .
TEAMWORK
FORM A TEAM OF PEOPLE,
THE PEOPLE THAT ACTUALLY
DO THE WORK
IDEAS
OBSERVE
THE TEAM DEVELOPS IDEAS
ON HOW TO ELIMINATE
WASTE
ANALYZE THE CURRENT
SITUATION
COMMUNICATION
MAKE SURE EVERYONE KNOWS
THE GOALS, THE CHANGES
BEING MADE, THE SUCCESSES,
AND THE FAILURES
CULTURE
CREATE A CONTINOUS
IMPROVEMENT CULTURE.
ALWAYS CONSIDER NEW IDEAS
Manufacturing Waste . . .
DEFECTS
WAITING
Any non-work time
waiting for tools,
supplies, parts, etc..
Repair or
Rework.
Any wasted motion
to pick up parts or
stack parts. Also
wasted walking.
PROCESSING
Doing more work than
is necessary.
EXCESS
MOTION
Types
of
Waste
UNDERUTILIZED
PEOPLE
OVERPRODUCTION
Producing more
than is needed
before it is needed.
TRANSPORTATION
Waiting for more
Work to do.
INVENTORY
Maintaining excess
inventory of parts in
process, or
finished goods.
Transporting parts, or
finished goods into or
out of storage, or
between processes.
the operations.
We
We
the operations.
We
the operations.
VALUE STREAM MAP
Finding
Waste
Lean Manufacturing Tools . . .
Visual Management
Level Loading
Batch Reduction
Standardized Practice
VSM
Pull Systems
5S
Poka Yoke
Just in Time
Kaizen
Quick Changeover
Total Productive
Maintenance
Lean Video. . .
“A vision without a
plan is just a dream,
a plan without a vision
is a nightmare”.
Thank you.
- Engr. Michael John B. Rubi -