This document discusses lean manufacturing. It defines lean manufacturing as a system aimed at eliminating waste from all activities and operations. The goal is to produce products faster, better, and cheaper than competitors while eliminating as much waste as possible. The seven types of waste are then defined: transport, inventory, motion, waiting, overproduction, overprocessing, and defects. Examples are provided for each type of waste.
1. UNIVERSITI KUALA LUMPUR
MALAYSIAN INSTITUTE OF INDUSTRIAL TECHNOLOGY
JFB 30103 MINTENANCA PLANNING CONTROL:
LEAN MANUFACTURING
PREPARED BY : SYED SHAHRUL NIZAM BIN SYED AHMAD
57296113596
BET FAME / 01
LECTURER’s NAME : EN ADNAN BIN BAKRI
2. WHAT IS LEAN MANUFACTURING
Lean Production or Lean Manufacturing is a
manufacturing/production system best characterized as relentlessly
eliminating waste from all of its’ activities and operations.
Lean strives to produce products (and deliver services):
1. On-Time
2. Using as few resources as possible
3. Better than competitors
4. Faster & Cheaper than competitors
5. While Eliminating as MuchWaste as Possible
3. WHAT IS LEAN MANUFACTURING
Lean production is aimed at the elimination of waste in
every area of production including customer relations,
product design, supplier networks and factory management
Its goal is to incorporate less human effort, less inventory,
less time to develop products, and less
space to becomehighly responsive to customer demand
while producing top quality products in the most efficient and
economical manner possible.
4. FUNCTION OF LEAN MANUFACTURING
Production Flow
Products, workflow, equipment and support
It is focused on defining products, equipment and
workflows that can be produced in small lot production
runs being “pulled’ by downstream
customer demands
It is oriented to getting the product to the customer in
the shortest period of time and at the lowest cost with
superior quality and customer satisfaction
5. FUNCTION OF LEAN MANUFACTURING
Planning
The separation of:
Material Requirement Planning (MRP) System function:
(Reconciliation – the process of high-level demand planning
and scheduling) form
Day-to-day planning functions (Regulation – the process of
regulating command and control sequences within a pull-process
environment capable of controlling “workable work”
for each production unit and production cell.
MRP must also project intermediate and long-range procurement
objectives to suppliers.
The day-to-day and shift-by-shift operations will need a real-time
Plant Operations Control system (POC)
satisfaction
6. FUNCTION OF LEAN MANUFACTURING
Organization
Lean Production demands a re-thinking of the structure,
role and responsibility of each individual within the
organization.
The formation of Production Units operating as
“Business Units” & Flat Organization will help to
understand the needs of their customers and organize all
resources, products and capabilities to support and add
value to its customers needs and expectations.
7. FUNCTION OF LEAN MANUFACTURING
Performance Measures
Performance Measures must be developed in a hierarchy
that is cascaded upward and downward within the
organization.
The measures should be understandable, simple to
administer and enable management and team members to
easily make decisions and take action when appropriate.
8. LEAN GOALS AND STRATEGY
Improve quality : To stay competitive in today's
marketplace, a company must understand its customers'
wants and needs and design processes to meet their
expectations and requirements.
Eliminate waste : Waste is any activity that consumes
time, resources, or space but does not add any value to
the product or service.
11. TRANSPORT
Transport is one of the seven waste of lean manufacturing, it is the
movement of products from one location to another.
This transportation adds no value to the product, it does not transform it
and the customer would not be happy in paying for it!
Examples of wastes of Transport
1. The transport of product from one functional area such as pressing, to
another area such as welding.
2. The use of material handling devices to move batches of material from
one machine to another within a work cell.
3. The shipment of product from one “functional” factory to another.
4. The transportation of “cheaper” components from one country to
another.
13. INVENTORY
Inventory is the raw materials, work in progress (WIP) and
finished goods stock that is held.
Inventory can be observed in many areas of a business, as either
raw materials that have been ordered in excess of customer
requirements due to mistrust of suppliers or to take advantage of
“bulk discounts” to the large amounts of finished goods sitting in
your warehouse just in case a customer orders them
15. MOTION
Waste being a process step that is not value adding, moving is not necessarily
working.
Examples of wastes of motion
1. A machine that travels excessive distance from start point to where it begins
work.
2. Heavy objects placed on low or high shelves.
3. Searching for tools and equipment.
4. Walking across work space to retrieve components or use machines.
5. Constantly turning and moving product during assembly.
6. Having to reorient component when taken from its location.
7. Reaching excessive distances when taking components and tools.
17. WAITING
It is the act of doing nothing or working slowly whilst waiting for a
previous step in the process
Mostly they are waiting for one another, which often happens because
they have non-aligned objective.
Examples of wastes of Waiting
1. Operators / Machines standing idle whilst they wait for a previous
processes production to be sorted due to quality problems.
2. Waiting for a breakdown to be resolved.
3. Waiting for the forklift truck to deliver a batch of components.
4. Waiting for information from the engineering department.
5. Waiting to be told which product is required next.
19. OVER PRODUCTION
overproduction is making products in too great a quantity or before it is actually
needed leading to excessive inventory.
However, producing more than "just enough" or "just-in-time" inventory drives
up the costs of inventory and results in scrap if demand does not equal supply
— wasting all the value if the excess products must be scrapped or sold at a loss
21. OVER PROCESS
Overprocessing is adding more value to a product than the
customer actually requires such as painting areas that will never be
seen or be exposed to corrosion.
Examples of wastes of Overprocessing
1. Painting areas that will never be seen or be affected by corrosion.
2. Over polishing an area that does not require it.
3. Tolerances that are too tight.
23. DEFECT
Defects are when products or service deviate from what the
customer requires or the specification. When you talk about waste
most people think of defects rather than the other wastes such as
waiting and transportation.
Examples of wastes of Defects
1. Scrap produced by poorly maintained fixtures.
2. Parts assembled with the incorrect orientation.
3. Missing screws and other fixing due to lack of controls.
