Lean Manufacturing Concepts and Tools and Quality ManagementBy Hristina Koycheva

What is Lean?Lean is an Operational Excellence Strategy that enable you to change for the better- in fact the Japanese often use Kaizen which use by lean practitioners to describe incremental improvements ;

What is Lean?Persistent process in elimination of waste MUDA describes any activity thats done, but add no real value to the product or service.

What is Lean?Respect for peopleHigh Quality and Stable Processes

Where?At all level there is a strong desire to be better;A culture of lean is visibly prioritised and practice from the top to the bottom of the workforce;The key is understanding the customer and delivering his requirements;

How?Improves business performance using simple practical tools and techniques to enhance quality, cost, delivery and people contribution;Exposes the wastes in the system;People need to change their long standing work practices and ideas;Senior management need to drive lean principles forward with total commitment to its success;Not a bolt on technique, more a way of life leading to a total change in culture.

Short History1913: Henry Ford (Start of mass manufacturing with the moving line)

1938 JIT Born

Short History1950: Eiji Toyoda brings the ideas of continuous moving line in Japan

Short History1960: Toyota production System, main principles of lean manufacturing

1991: Lean Management

Main PrincipalsIdentify the customerMap the flowMake a product or service flowCreate polls based on customer demandsContinually find ways to improve

Lean ToolsAssessment and planning- fundamentals and understanding where we are today and creating and design for tomorrow.

Plan, Do, Check, Act

Lean Tools5 S

Visual control

Standardize work

Total productive maintenance

Select the keyReduce cost of production

Increase customer satisfaction

Improve qualitySelect the keyMap Process

Eliminate Waste

Make Process Flow

Establish Customer Poll

What Is Waste?Waste of overproduction (largest waste)Waste of time on hand (waiting)Waste of transportationWaste of processing itselfWaste of stock at handWaste of movementWaste of making defective products

Lean ThinkingKey Principals of Lean ThinkingValue - what customers are willing to pay for;

Value Stream the steps are delivered value;

Flow organizing Value Stream to be continuous;

Polls responding to downstream customer demand;

Perfection relentless continuous improvement (culture);

Lean Thinking, Womack and Jones,1996

ConclusionLean is:

A systematic approach to identifying and eliminating waste (non-value added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection.

Production SystemTwo pillars:

Jidoka

Just-in-time

What is Jidoka?Jidoka means autonomous. The responsibility of each associate to deliver Quality to the customers.- Intense Motivation Training;- Explained Information;

Just-in-timeAims of zero inventory;

Parts are not kept in warehouse;

Parts arrive when needed;

Quality systemQuality means compliance with specifications- no less, no more;No need for inspections!

Quality AssuranceWhen we focused on this we will consistently deliver what the customer expects;

Trust raises everyones commitment

Thank you!