WELCOME TO THE PRESENTATIONON
APPLICATIONS OF LEAN APPROACH
IN MANUFACTURING
COURSE NAME: Business Communication SeminarCOURSE NO: IPE-326
PRESENTED BYMEMBER’S NAME REG NO:
Ismam Ahmed 2012334062
Musaddeque Hossain 2012334063
Reduan Islam Hridoy 2012334065
Sabbir Ahmed 2012334064
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERINGSHAHJALAL UNIVERSITY OF SCIENCE &TECHNOLOGY,
SYLHET
CONTENTS What is lean?Component of lean manufacturing7 types of wastesOrigin of lean5SBatch size reductionKanbanKaizanVisual contents(Andon,Footprint,Signage)Cellular plantLean in Bangladesh
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
TPS Definitions of Waste(7 types)
1. Overproduction2. Waiting, including time in
queue3. Transportation (between
workstations, or between supplier and customer)
4. Non-value-adding activities5. Inventory6. Waste motion7. Cost of poor quality: scrap,
rework, and inspection
“Anything that adds Cost to the product without adding Value”
Team work
Origin of Lean
Statiscal Process ControlPlan-Do-Check-Act cycle
Ass
embl
y lin
eS
tand
ardi
zed
Wor
kTi
me
stud
y
Interchangeable parts
Work Division
“Doing more with less”
JITJidokaKaizenSMED
Pull system
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
Lean ToolsWorkplace 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)
Inventory level
Delivering smaller quantities can reduce inventory levels
Inventory level
Batch Size Reduction
Lower Scrap
Lower holding cost
Space utilization
Higher productivity
Jidoka(Autonomation)
AutonomationAutomation
+ 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
Plate
B
Jidoka(Autonomation)
SIGNBOARD
KAN署名する BANボード+
=
KANBAN
Is a “signal” that: Authorizes production Authorizes movement Visualize current position Drives continuous improvement
Pigon hole Signal Sticky notes box
KANBAN
Pending Analysis Development TestDoing Done Doing Done
p11p22
p17
p15
p13p5
p8
p2
p9
p10
p7
p1
p3p6
Where is Product-3 now?
Search the hole plant
Check Kanban list
5S (workplace organization)
Organisation/Sort out
SEIRI
Orderliness/Systemize
SEITONStandardize
SEIKETSUSustain/
Discipline
SHITSUKEThe 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
5S Effect on Office
Clean top
Similar papers in files
Paper arranged
SEIRI SEITON SEISO SEIKETSU SHITSUKE
VISUAL CONTROLVisual Controls are simple signals that provide an immediate understanding of a situation or condition.
lightingSystem
Floor painting
PictureDiagram
Color coded tool
Andons SignageFootprint
Basically 3 types
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 Andon2
ANDON
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
SIGNAGE
Provide information about:•hazardous and risky areas & installation• materials• safety measures• emergency exits, etc.
Signage
Displays Control
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
Cellular Layout
• Produces families of parts within a single line• Reduce cycle time• Reduce time wastes
Storage
Drilling
joint
Threading
Turning PackingData
45%
65%
Assembly
check
Quality
Functional layoutCelluar Layout© Siemens Power Generation Systems
Reduction in unit production costCompany 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.
8.5011.04.40 10.01.403.500.87-4.50
7.009.003.208.001.303.000.84-3.00
1.502.001.202.000.100.500.03-1.50
17.618.127.220.07.114.23.4-33.3
Application of lean in Bangladeshi companies
Removes unnecessary activities Removes in-plant inventory Removes in-transit inventory Improves quality and reliability
JUST IN TIME (JIT)
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
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:
Examples of POKE-YOKE
THANK YOU
ANY QUESTION?