Lean Tools application with powerpoint animation. all processes are easily described with images & animation. Uploaded by Ishmam Ahmed Industrial & Production Engineering (IPE) Shahjalal university of science & Technology, Sylhet, Bangladesh

1. WELCOME TO THE PRESENTATION
ON
APPLICATIONS OF
LEAN APPROACH
IN
MANUFACTURING

2. COURSE NAME: Business Communication Seminar
COURSE NO: IPE-326
PRESENTED BY
MEMBER’S NAME REG NO:
Ismam Ahmed 2012334062
Musaddeque Hossain 2012334063
Reduan Islam Hridoy 2012334065
Sabbir Ahmed 2012334064
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
SHAHJALAL UNIVERSITY OF SCIENCE &TECHNOLOGY, SYLHET

3. CONTENTS What is lean?
Component of lean manufacturing
7 types of wastes
Origin of lean
5S
Batch size reduction
Kanban
Kaizan
Visual contents(Andon,Footprint,Signage)
Cellular plant
Lean in Bangladesh
1

4. It is a comprehensive set of techniques that are
used to identification and stady elimination of
wastes,improvement of quality,reduction of
production and cost
What is lean
Elimination of waste
Improve of quality
Identification
Reduction cost
2

5. TPS Definitions of Waste(7 types)
1. Overproduction
2. Waiting, including time in
queue
3. Transportation (between
workstations, or between
supplier and customer)
4. Non-value-adding activities
5. Inventory
6. Waste motion
7. Cost of poor quality: scrap,
rework, and inspection
“Anything that adds Cost to the product without adding Value”
3

6. Team work
Origin of Lean
Statiscal Process
Control
Plan-Do-Check-Act
cycle
Assembly
line
StandardizedWork
Timestudy
Interchangeable parts
Work
Division
“Doing more with
less”
JIT
Jidoka
Kaizen
SMED
Pull system
4

7. Waste is Often Built Into Jobs
Gilbreth study on brick setup
Need 7-8 sec to setup a single brick Need 2-3 sec to setup a single brick
5

8. Lean Tools
Workplace Organization: 5S
Lean
Tools
Kanban
Kaizen
Work balancing (TAKT Time)
Visual Management
Set-up Eeduction (SMED)
Heijunka
Batch Size Reduction
Standardized Work
Error-Proofing (Poka-Yoke)
Total Productive Maintenance (TPM)
Jidoka (autonomotion)
6

9. Inventory level
 Delivering smaller quantities can reduce inventory levels
Inventory level
Batch Size Reduction
Lower Scrap
Lower holding cost
Space utilization
Higher productivity
7

10. Jidoka(Autonomation)
Autonomation
Automation
+
Human
intelligence
A level of human intelligence is transferred into automated machinery
Practice of stopping a manual line or process automatically
Frees the operator from watching the machine
8

11. Jidoka(Autonomation)
9

12. Before
JIDOKA
After
Jidoda
SUSTIPE
Stopped
10

13. SIGNBOARD
KAN
署名する
BAN
ボード
+
=
KANBAN
Pigon hole Signal Sticky notes box
11

14. KANBAN
Pending Analysis Development Test
Doing Done Doing Done
p11
p4
p12
p14
p13
p5
p8
p2
p9
p10
p7
p1
p3
p6
Where is Product-3 now?
Search the hole
plant?
Check Kanban list?
12
p1 p2 p3 p4 p5 p6 p7 p8 p9 p10 p10 p11 p12 p13 p14

15. 5S (Workplace Organization)
Organisation/
Sort out
SEIRI
Orderliness/
Systemize
SEITON
Standardize
SEIKETSU
Sustain/
Discipline
SHITSUKE
The Cleaning/
Shining
SEISO
 Developed by the Japanese
 Housekeeping System
 Helps Create a Better Working Environment and a Consistently High Quality Process
 Make faster assembly plant
13

16. 5S Effect on Office
Clean top
Similar
papers in
files
Paper
arranged
SEIRI SEITON SEISO SEIKETSU SHITSUKE
14

17. VISUAL CONTROL
lighting
System
Floor
painting
Picture
Diagram
Color
coded
tool
Andons SignageFootprint
15

18. Types of Andon
Coded signal lightsText Graphics
Visual Andon
Green - no problems
Yellow - situation requires
attention, production flow at risk
Red - PRODUCTION STOPPAGE:
IMMEDIATE ASSISTANCE
REQUIRED
1
 Display production data in
real time.
 Calculate shift efficiencies
and production targets.
 Ideal for STOP /
WAIT / GO signaling
in busy factories
 Boost health and
safety.
Coded
Tones
Coded
Tunes
Prerecorded
Messages
Buzzers
/ Alarms
Audio Andon
2
ANDON
16

19. FOOT-PRINT
 avoids employees wasting time looking for things
 The workplace becomes clean and better organized.
 Operation on the shop floor and office become easier and safer
Use colours as a guideline :
Light Blue - Raw parts/material
Black - Finished good/parts
Red - Non-conforming/KIV parts/material
White - Other than parts/material
Yellow – Border of work area
17

20. SIGNAGE
Provide information about:
•hazardous and risky areas & installation
• materials
• safety measures
• emergency exits, etc.
Signage
Displays Control
18

21. KAIZEN
ACT
Check
Do
Plan
Customar
Need
Kaizen
• is a tool to rapidly improve work as part of the PDCA cycle
• is a tool for Continuos process
• goals must align with the business objectives
KAI ZEN = Change for the better
19

22. Cellular Layout
• Produces families of parts within a single line
• Reduce cycle time
• Reduce time wastes
Storage
Drilling
joint
Threading Turning
Packing
Data
45
%
65
%
Assembly
check
Quality
20

23. Functional layoutCelluar Layout
© Siemens Power Generation Systems
21

24. Reduction in unit production cost
Company Name Before
Lean
($)
After
Lean
($)
Reduction
($)
As a %
1. Fashion Point Ltd.
2. Texas Fashion Ltd.
3. Beximco Fashions Ltd.
4. Shanta Industries Ltd.
5. DADA (Savar) Ltd.
6. Shata WashWorks Ltd.
7. Armana Fashions Ltd.
8. Shanta Denims Ltd.
9. PAXAR Bangladesh Ltd.
8.50
11.0
4.40
10.0
1.40
3.50
0.87
-
4.50
7.00
9.00
3.20
8.00
1.30
3.00
0.84
-
3.00
1.50
2.00
1.20
2.00
0.10
0.50
0.03
-
1.50
17.6
18.1
27.2
20.0
7.1
14.2
3.4
-
33.3
Application of lean in Bangladeshi companies
22

25.  Removes unnecessary activities
 Removes in-plant inventory
 Removes in-transit inventory
 Improves quality and reliability
JUST IN TIME (JIT)
23

26. Traditional approach
JIT approach
stage A
orders
deliveries
orders
deliveries
JIT material flow
buffer
inventory
stage B
buffer
inventory
stage
C
stage A stage Cstage B
24

27. POKA-YOKE(ERROR PROOF)
POKA-YOKE is part of the Just-in-time philosophy
POKA-YOKE reduces the defect rate that is part of the OEE rate
 Weight
 Dimensions
 Shape
Suggested Methods:
25

28. Examples of POKE-YOKE
26

29. THANK
YOU
ANY
QUESTIONS?