ppt

1. Apparel Quality Management
Assignment
“Lean manufacturing”
Presented by:
1. Esubalew Gebrie
2. Getahun Gebreyesus
3. Mickyas Zewdie

2. Contents
 Lean definition
 Lean philosophy
 Lean goal
 Types of Waste
 Essential lean tools
 Steps of lean implementation
 Lean Manufacturing Implementation Facts and Figures
 Risks of Implementing Lean
 Conclusion
 Reference

3. What is Lean
 Lean is a philosophy, an improvement process,
a way of leading, a business strategy, a
competitive advantage, a means to save
manufacturing.
 What lean means to me is the belief that we
can make the world a better place one small
improvement at a time, by identifying and
eliminating waste from all that we do.

4. Lean Philosophy
A. Customer First
Lean always focused on customer
satisfaction
B. People are the most valuable resource
A. Continuous Improvement
B. Shop floor focus

5. The Lean Goal
 Highest Quality
 Lowest Cost
 Shortest Lead-time

6. Types of Waste
Waste is divided into 8 Categories
D – Defects
O – Over Production
W – Waiting
N – Non utilization of human potential
T – Transportation
I – Inventory
M – Motion
E – Excess Processing

7. Cont.….

8. Essential lean tools

9. 5S
What is 5S? Organize the work area:
How does 5S help?
Eliminates waste
that results
from a poorly
organized
work area
(e.g. wasting
time looking
for a tool).

10. Just-In-Time (JIT)
What is Just-In-Time?
Pull parts through production based on customer demand
instead of pushing parts through production based on
projected demand.
How does Just-In-Time help?
 Highly effective in reducing inventory levels.
 Improves cash flow and reduces space requirements.

11. Kaizen (Continuous Improvement)
What is Kaizen?
 A strategy where employees work together proactively
to achieve regular, incremental improvements in the
manufacturing process.
How does Kaizen help?
 Combines the collective talents of a company to create
an engine for continually eliminating waste from
manufacturing processes.

12. 3 M

13. Single-Minute Exchange of Dies (SMED)
What is Single-Minute Exchange of Dies?
Reduce setup (changeover) time to less than 10 minutes. Techniques
include:
 Convert setup steps to be external (performed while the process is
running)
 Simplify internal setup (e.g. replace bolts with knobs and levers)
 Eliminate non-essential operations
 Create Standardized Work instructions
How does Single-Minute Exchange of Dies help?
Enables manufacturing in smaller lots, reduces inventory, and
improves customer responsiveness.

14. Steps of lean implementation
Step 1: Specify Value
which product meets the customer's needs at a specific
price and at a specific time
Step 2: Map
Identify the value stream
Step 3: Flow
Step 4: Pull
Step 5: Perfection
Return to the first step and begin the next
lean transformation

15. Lean Manufacturing Implementation
Facts and Figures
 DELIVERY +26%
 STOCK TURNS +33%
 PRODUCTIVITY +25%
 SCRAP -26%
 SPACE -33%

16. Conclusion
 As of today, is it widely accepted that lean is for everyone
 If it is not effectively applied, it will incur loss of income
to the organizations and under-serving the customer’s
requirements.
 The achievement of effective execution of lean
manufacturing is not only reliant on the correct usage of
tools of lean manufacturing but establishing for lean
manufacturing system and planning for its application is
very vital.
 It is very important for top management and all others to
understand lean thinking and lean principles.

17. Reference
1. Taiichi Ohno, Toyota Production System: Beyond
Large-Scale Production, 1988 Mekong Capital’s
Introduction to Lean Manufacturing, June 4, 2004.
2. www.technopak.com
3. Bon A.T and Rahman N.A, Quality Measurement in
Lean Manufacturing, International Conference on
Instrumentation, Communications, Information
Technology and Biomedical Engineering (ICICI –
BME), 2009, 1-7.