lean manufacturing

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					Contemporary Issue On
     What is lean manufacturing ???.

  Lean manufacturing evolved out of lean thinking which means
removal of waste.

  Waste specifically means any activity which absorbs resources
but creates no value.

   Lean manufacturing is a systematic approach for identifying and
eliminating waste in operations through continuous improvement.
• Pre 20th century

• 20th century

• Ford starts the ball rolling

• Toyota develops lean thinking
Techniques of Lean manufacturing

“ A management philosophy which seeks to
  integrate all organizational functions (
  marketing, finance, design, engineering,
  production, customer service….) to focus on
  meeting customer needs and organizational
• Just-in-time (JIT) is an inventory strategy
  implemented to improve the return on
  investment of a business by reducing in-process
  inventory and its associated Carrying costs.
• KAIZEN is Japanese word for improvement.
  Kaizen was first implemented in several
  Japanese businesses during the country's
  recovery after World War II, including Toyota,
  and has since spread to businesses throughout
  the world.
SEIRI:- Sorting
SEITON:- Simplifying
SEISO:- Sweeping, systematic cleaning or
SEIKESTSU:- Standardizing
SHITSUKE:- Sustaining
• The term six sigma comes from the field of
  statistics. Six Sigma approach has broadened to
  include such things as programme and project
  management tools and rules all of which are
  complementary to lean manufacturing.
Kanban means "sign" in Japanese, and is a visual
reactive re-order point control system.

Another lean manufacturing tool, which is focused
on the objective of zero breakdowns.

There are two types of manufacturing system
 simulation: computer and manual. This approach
enables operators to "buy-in" to the design of
the manufacturing system.

Over production
Order processing
                 CASE STUDY
In 1986 Motorola invented Six Sigma, a quality and business
improvement methodology that is revolutionizing industry.Two
decades and two Malcolm Baldridge Awards later, Motorola is
still finding new ways to reinvent itself using this techniques.
     Dan Tegel, Global Director, Digital Six Sigma Business
Improvement Motorola
 In 1980s US economy was facing
downtrend as companies like Motorola
were experiencing many problems.

 Like increasing complaints about
warranty claims for defective products.

  Motorola sold its TV division Quasar
to Matsushita, which is a Japanese
electronic company.
  They found that Japanese management focused on
preventing errors at the source therefore
dramatically reduces the defects and the cost for
rectifying them.

  In 1987 Galvin launched a long term quality
program called “The Six Sigma Quality Program”.

  By 1992, Motorola aimed to achieve the overall
quality level of 5.4 defects per million, a little less
than Six Sigma which is 3.4 defects per million
Upper management at the time generally thought
increasing quality meant increasing cost. The use of Six
Sigma proved the opposite was true. One of Motorola’s
most significant contributions was to change the discussion
of quality from the one where quality levels were measured
in percentages (parts per hundred) to a discussion of parts
per million. During inspiration from Motorola, many other
corporates across the world began to adopt the Six Sigma
methodology and the concept began to be loosely
described as “ The Second Industrial Revolution.”

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