lean production
TRANSCRIPT
Lean Production
• Less time, inventory, space, labor, and money
• eliminating waste, simplifying procedures and speeding up production.
• also known as Toyota Production System
• Toyota was able to greatly reduce leadtime and cost using the TPS (Toyota Production System), while improving quality at the same time
Lean Production
Systematic elimination of the 7 types of waste:
• Overproduction• Waiting• Transportation• Inventory• Motion• over-processing, • defective products
The japanese call it Muda (in Eng: Wastage)
Benifits
• Waste reduction by 80%
• Production cost reduction by 50%
• Manufacturing cycle times decreased by 50%
• Labor reduction by 50% while maintaining or increasing throughput
• Inventory reduction by 80% while increasing customer service levels
Benifits
• Capacity in current facilities increase by 50%
• Higher quality
• Higher profits
• Higher system flexibility in reacting to changes in requirements improved
• More strategic focus
• Improved cash flow through increasing shipping and billing frequencies
Kaizen
• philosophy of continual improvement
• involving everyone – managers and workers Management has two major components:
• maintenance, and • improvement
Poka-Yoke
• defect warning system
• make it impossible to make mistakes
• initial term was baka-yoke, which means ‘fool-proofing’
• improve quality and reliability
• can eliminate both human and mechanical errors
Kanban
• to achieve Just-in-time
• pulls just the number and type of components the process requires
• physical card or other devices
Jidoka
• meaning “automation with a human touch”
• quality control process • four principles:
• Detect the abnormality • Stop • Fix or correct the immediate condition• Investigate the root cause and install a
countermeasure
Jidoka
• Jidoka involves the automatic detection of errors or defects during production
• helps to detect a problem earlier and avoids the spread of bad practices
