Lean Manufacturing Technique For Stuff As Well As Garments Manufacture | Removal Of Wastes Through Lean
Monday, 16 June 2014
Edit
Lean Manufacturing
Lean manufacturing is a systematic approach to identifying as well as eliminating wastes through continuous improvement past times conveying the production at the line of the client inward pursuit of production.
Lean manufacturing is a systematic approach to identifying as well as eliminating wastes through continuous improvement past times conveying the production at the line of the client inward pursuit of production.
Lean Manufacturing is a systematic approach for achieving the shortest possible cycle fourth dimension past times eliminating the physical care for waste materials through continuous improvement. Thus making the functioning rattling efficient as well as exclusively consisting of value adding steps from start to finish. In uncomplicated words lean is manufacturing without waste.
Below are the few steps which are required to implement lean manufacturing
- Identifying the fact that at that topographic point are wastes to last removed.
- Analyzing the wastes as well as finding the root causes for these wastes.
- Finding the solution for these root causes.
- Application of these solutions as well as achieving the objective.
Lean vs Traditional Manufacturing Process:
For years manufacturers receive got created products inward anticipation of having a marketplace position for them. Operations receive got traditionally been driven past times sales forecasts as well as firms tended to stockpile inventories inward instance they were needed. Influenza A virus subtype H5N1 primal departure inward Lean Manufacturing is that it is based on the concept that production tin as well as should last driven past times existent client demand.A lean arrangement tin brand twice every bit much production alongside twice the character as well as one-half the fourth dimension as well as space, at one-half the cost, alongside a fraction of the normal work-in-process inventory. Lean management is near operating the most efficient as well as effective arrangement possible, alongside to the lowest degree cost as well as null waste
THE LEAN PRODUCTION GOALS:
The principal goal of lean manufacturing is to create a continuous menses of Product from raw textile to finished goods as well as on to the client – no stoppages, no delays, no Interruptions because of inventory combat or yield issues, downtime or the other problems that travel on inward a typical manufacturing operation.
The principal goal of lean manufacturing is to create a continuous menses of Product from raw textile to finished goods as well as on to the client – no stoppages, no delays, no Interruptions because of inventory combat or yield issues, downtime or the other problems that travel on inward a typical manufacturing operation.
- Maximizing value (give the client what they just need)
- Minimizing waste materials (eliminate anything non needed for delivering value)
- Pursuing perfection
- Reduce Time
- Reduce Total Costs
Cost Reduction past times Elimination of Waste
It requires constant attempt at cost reduction to maintain continuous profits inward manufacturing. The prime number way to trim down costs is to create exclusively those products determined past times sales inward a timely fashion, to confine excessive manufacturing as well as to eliminate all waste materials inward manufacturing methods. There are diverse ways to analyze as well as implement cost reduction, from the start of designing all the way through to manufacturing as well as sales. One of the goals of Lean Manufacturing is to locate waste materials pragmatically inward each physical care for as well as so eliminate it. It is possible to uncover a rattling large amount of waste materials past times observing employees, equipment, materials as well as arrangement inward the actual production business from the perspectives of the physical care for itself as well as the actual piece of work involved. Some types of waste materials are obvious, but others are hidden. Waste never improves value; it exclusively increases cost. The thorough elimination of waste materials leads to greater employee self-respect as well as to major cost reductions past times preventing unneeded losses.
Creating Conditions to Guarantee Product Quality
To create a high-quality production is the firstly commandment of whatever manufacturing company. The high character of whatever product, inward which many element as well as parts practise non neglect as well as are problem free, must last built into it at every process. Lean Manufacturing has developed diverse ways to back upwards the commitment to “build the character into the process.” This regulation gives each operator the responsibleness to depository fiscal establishment check character thoroughly at every phase of piece of work inside the process, as well as brings production inspection straight into the physical care for so that expert products menses to the next physical care for as well as defects are extracted at that point. Each operator must last aware that “the next physical care for is a customer” as well as must never mail a defective production to downstream processes. If equipment is defective or operates abnormally, either the machine itself or some scheme must last able to uncovering the work as well as halt operation. Foolproof devices are often used every bit uncomplicated agency for this purpose. This also makes it easier to maintain quality. Lean Manufacturing has taken many measures as well as expended much attempt to catch that, if a defect inward character should occur, nosotros tin uncover the truthful drive as well as apply countermeasures to foreclose its recurrence.
Creating a Work Site alongside Operators inward Mind
If labor is expended on a production but does non contribute whatever additional value to it, that labor is of no value. On the other hand, if the labor expended on a production enhances the product’s value, so that labor is of peachy value because it is effective. This type of effective labor usage translates into showing observe for human dignity, the dignity of the employee. In the Lean Manufacturing measures receive got been taken so that the labor or every employee will
heighten the value of our products. One of these measures is Standardized Work. This is a way to perform the most effective sequential production without waste materials past times rationally concentrating the piece of work unopen to the Operators’ movement. Some companies usage a scheme that stresses the performance of equipment as well as machines. In this case, the equipment is considered to last of prime number importance as well as the employee mere expansion of the machine. Mutual back upwards is indispensable if each employee, who plays the leading role for his item task, is to perform the piece of work as well as meliorate the efficiency of the whole production process. In Lean Manufacturing the implementation of usual back upwards betwixt the preceding as well as succeeding processes has affected highly efficient work. If the Operator discovers some work inward the piece of work for which he is responsible, he or she is permitted to halt the business depending on the gravity of the problem. This is exclusively possible against
a backdrop of observe for the judgment as well as tidings of the employees. Influenza A virus subtype H5N1 piece of work site, where every employee tin fully display his ain ability, tin last created alongside a scheme inward which the piece of work accomplishments of each private are a thing of populace knowledge, as well as anyone tin suggest kaizen for piece of work problems.
Awareness of Waste
Cost Reduction versus Cost Plus
Lean Manufacturing improves productivity through the regulation of Cost Reduction.
With the regulation of cost reduction, the sales cost of a production is determined past times actual market
conditions. Influenza A virus subtype H5N1 net cannot last secured, thus, without firstly reducing cost regardless of increases
or decreases inward the production quantity. This type of cost philosophy requires an overall
society effort. Cost reduction is:
Profit = Sales cost – Cost
In contrast to cost reduction, at that topographic point is the cost-plus principle, inward which production cost is
determined past times combining all the costs -- such every bit those of raw materials, labor as well as other
expenses needed for production -- alongside whatever society policy decides is needed every bit profit.
Cost policy:
Sales cost = Cost + Profit
The 2 formulas inward a higher house are the same mathematically, but at that topographic point is a peachy departure inward the
emphasis each i places on the variables. In other words, cost-plus considers that the cost is
fixed. While cost reduction considers, that the cost tin last effectively changed by
manufacturing methods.
Main Kinds of Wastes
Seven principal types of wastes were identified every bit a component of the Toyota Production System. However, this listing has been modified as well as expanded past times diverse practitioners of lean manufacturing as well as mostly includes the following:
Overproduction
It is unnecessary to create to a greater extent than than the client demands, or producing it also early on earlier it is needed. This increases the adventure of obsolescence as well as the adventure of producing the wrong thing. It tends to Pb to excessive Pb as well as storage times. In addition, it leads to excessive work-in-process stocks which termination inward the physical dislocation of operations alongside consequent poorer communication
Defects
In add-on to physical defects which straight add together to the costs of goods sold, this may include errors inward paperwork, belatedly delivery, production according to wrong specifications, usage of also much raw materials or generation of unnecessary scrap. When defect occurs, rework may last required; otherwise the production volition last scrapped. Generation of defects volition non exclusively waste materials textile as well as labor resources, but it volition also create textile shortages, hinder coming together schedules, create idle fourth dimension at subsequent workstations as well as extend the manufacturing Pb time.
It is unnecessary to create to a greater extent than than the client demands, or producing it also early on earlier it is needed. This increases the adventure of obsolescence as well as the adventure of producing the wrong thing. It tends to Pb to excessive Pb as well as storage times. In addition, it leads to excessive work-in-process stocks which termination inward the physical dislocation of operations alongside consequent poorer communication
Defects
In add-on to physical defects which straight add together to the costs of goods sold, this may include errors inward paperwork, belatedly delivery, production according to wrong specifications, usage of also much raw materials or generation of unnecessary scrap. When defect occurs, rework may last required; otherwise the production volition last scrapped. Generation of defects volition non exclusively waste materials textile as well as labor resources, but it volition also create textile shortages, hinder coming together schedules, create idle fourth dimension at subsequent workstations as well as extend the manufacturing Pb time.
Inventory
It agency having unnecessarily high levels of raw materials, works-in-process as well as finished products. Extra inventory leads to higher inventory financing costs, higher storage costs as well as higher defect rates. It tends to increment Pb time, prevents rapid identification of problems as well as increment infinite requirements. In lodge to acquit effective purchasing, it is specially necessary to eliminate inventory due to wrong Pb times.
Transportation
It includes whatever motion of materials that does non add together whatever value to the product, such every bit moving materials betwixt workstations. Transportation betwixt processing stages results inward prolonging production cycle times, the inefficient usage of labor as well as space. Any motion inward the
firms could last viewed every bit waste. Double treatment as well as excessive movements are probable to drive harm as well as deterioration alongside the distance of communication between
processes.
Waiting
It is idle fourth dimension for workers or machines due to bottlenecks or inefficient production menses on the manufacturing works life floor. It includes minor delays betwixt processing of units.When fourth dimension is beingness used ineffectively, so the waste materials of waiting occurs. This waste materials occurs whenever goods are non moving or beingness worked on. This waste materials affects both goods as well as workers, each spending fourth dimension waiting. Waiting fourth dimension for workers may last used for preparation or maintenance activities as well as should non termination inward overproduction
It is idle fourth dimension for workers or machines due to bottlenecks or inefficient production menses on the manufacturing works life floor. It includes minor delays betwixt processing of units.When fourth dimension is beingness used ineffectively, so the waste materials of waiting occurs. This waste materials occurs whenever goods are non moving or beingness worked on. This waste materials affects both goods as well as workers, each spending fourth dimension waiting. Waiting fourth dimension for workers may last used for preparation or maintenance activities as well as should non termination inward overproduction
Motion
It includes whatever unnecessary physical motions or walking past times workers which divert them from actual processing work. This mightiness include walking unopen to the manufacturing works life flooring to expect for a tool, or fifty-fifty unnecessary or hard physical movements, due to poorly designed ergonomics, which ho-hum downwards the workers. It involves pathetic ergonomics of production, where operators receive got to stretch, curvature as well as pick upwards when such actions could last avoided.
It includes whatever unnecessary physical motions or walking past times workers which divert them from actual processing work. This mightiness include walking unopen to the manufacturing works life flooring to expect for a tool, or fifty-fifty unnecessary or hard physical movements, due to poorly designed ergonomics, which ho-hum downwards the workers. It involves pathetic ergonomics of production, where operators receive got to stretch, curvature as well as pick upwards when such actions could last avoided.
Over-processing
It is unintentionally doing to a greater extent than processing piece of work than the client requires inward damage of production character or features such every bit polishing or applying finishing inward some areas of production that volition non last seen past times the client . Over-processing occurs inward situations where overly complex
solutions are constitute to uncomplicated procedures. The over-complexity discourages ownership as well as encourages employees to overproduce to recover the large investment inward the complex machines.
The Eighth Waste – Skills
Sometimes inward focusing on the elimination of the 7 wastes, companies forget near the seem of Lean that is inherent inward the philosophy every bit it was originally developed inward Nihon – observe for people. In other words, the recognition that a company’s most of import assets are its employees. To that end, Lean practitioners sometimes add together an 8th waste materials to the listing – skills. This waste materials occurs when society does non fully leverage the gifts as well as talents of its associates. In fact, employees may fifty-fifty determine to leave of absence a society for the uncomplicated argue that they practise non experience every bit though they are beingness listened to or valued, and, every bit such, they experience similar a number inward a bounding main of numbers.
THE BASIC LEAN MANUFACTURING PRINCIPLES:
The five-step idea physical care for for guiding the implementation of lean techniques is slow to remember, but non ever slow to achieve:
It is unintentionally doing to a greater extent than processing piece of work than the client requires inward damage of production character or features such every bit polishing or applying finishing inward some areas of production that volition non last seen past times the client . Over-processing occurs inward situations where overly complex
solutions are constitute to uncomplicated procedures. The over-complexity discourages ownership as well as encourages employees to overproduce to recover the large investment inward the complex machines.
The Eighth Waste – Skills
Sometimes inward focusing on the elimination of the 7 wastes, companies forget near the seem of Lean that is inherent inward the philosophy every bit it was originally developed inward Nihon – observe for people. In other words, the recognition that a company’s most of import assets are its employees. To that end, Lean practitioners sometimes add together an 8th waste materials to the listing – skills. This waste materials occurs when society does non fully leverage the gifts as well as talents of its associates. In fact, employees may fifty-fifty determine to leave of absence a society for the uncomplicated argue that they practise non experience every bit though they are beingness listened to or valued, and, every bit such, they experience similar a number inward a bounding main of numbers.
THE BASIC LEAN MANUFACTURING PRINCIPLES:
The five-step idea physical care for for guiding the implementation of lean techniques is slow to remember, but non ever slow to achieve:
1. Value
Specify value from the standpoint of the destination client past times production family.
2. Value current mapping
Identify all the steps inward the value current for each production family, eliminating whenever possible those steps that practise non create value.
3. Flow
Make the value-creating steps travel on inward tight sequence so the production volition menses smoothly toward the customer.
4. Pull
As menses is introduced, permit customers line value from the side past times side upstream activity.
5. Perfection
As value is specified, value streams are identified, wasted steps are removed, as well as menses as well as line are introduced, get down the physical care for i time again as well as maintain it until a nation of perfection is reached inward which perfect value is created alongside no waste.
LEAN MANUFACTURING TOOLS & TECHNIQUES:
Here are some of the most of import tools of lean, ones that a typical lean practitioner must be
proficient it as well as capable of applying:
Here are some of the most of import tools of lean, ones that a typical lean practitioner must be
proficient it as well as capable of applying:
• Value Stream Mapping
• Takt Time
• EPEI
• Leveling (Heijunka)
• Pull Systems
• Setup Reduction
• Pokayoke (Mistake Proofing)
• 5S
• Seven QC Tools
• JIT
• Kanban
Value Stream Mapping
Value current mapping is the identification of all the specific activities (material as well as information
flow) every bit good every bit the resulting Pb times occurring along the value current for a item production or
production family, usually represented pictorially inward a value current map.
Takt Time
Takt fourth dimension is the charge per unit of measurement at which production must last turned out to satisfy marketplace position demand. It is determined
past times dividing the available production fourth dimension past times the charge per unit of measurement of client demand. It is a calculated number,
non a reflection of your capability. It sets the footstep of production to correspond the charge per unit of measurement of customer
demand.
EPEI
Influenza A virus subtype H5N1 mensurate of how oftentimes a physical care for tin create all the items assigned to it. For example, if a machine is able to alter over as well as create the required quantity of all the high-running component types dedicated to it inside 3 days, so the production batch size for each private component type is near 3 days worth of parts. Thus this machine is making every component every 3 days.
Leveling (Heijunka)
Leveling is the sequencing of orders inward a repetitive pattern, as well as the smoothing of day-to-day
variations inward total orders to correspond to longer-term demand.
Pull Systems
Influenza A virus subtype H5N1 line scheme is a scheme of production as well as delivery instructions inward which zippo is produced by
the upstream supplier until the downstream client signals a need. Pull tin operate alongside single
units or minor batches. It enables production without preset schedules.
checklists, worksheets, diagrams, expanse maps, etc., as well as may pertain to equipment use, operations,
processes, metrics, storage, safety, quality, motion inward an area, or full general usage of the environment.
Setup Reduction (Single Minute Exchange of Dies or SMED)
SMED is a serial of operator techniques pioneered past times Shigeo Shingo that termination inward changeovers of
production mechanism inward less than 10 minutes. The long-term objective is ever null setup, in
which changeovers are instantaneous as well as practise non interfere inward whatever way alongside one-piece flow.
Poka-yoke (Mistake Proofing)
Japanese term used past times Shigeo Shingo to hateful "innocent mistake-proofing," it is an improvement
applied scientific discipline that uses a device or physical care for to foreclose defects or equipment malfunction during
order-taking or manufacture. Mistake proofing devices are of import to the production business in
several ways:
(1) enforce right operations past times eliminating choices that Pb to wrong actions,
(2) signal or halt a physical care for if an error is made or a defect created
Influenza A virus subtype H5N1 mensurate of how oftentimes a physical care for tin create all the items assigned to it. For example, if a machine is able to alter over as well as create the required quantity of all the high-running component types dedicated to it inside 3 days, so the production batch size for each private component type is near 3 days worth of parts. Thus this machine is making every component every 3 days.
Leveling (Heijunka)
Leveling is the sequencing of orders inward a repetitive pattern, as well as the smoothing of day-to-day
variations inward total orders to correspond to longer-term demand.
Pull Systems
Influenza A virus subtype H5N1 line scheme is a scheme of production as well as delivery instructions inward which zippo is produced by
the upstream supplier until the downstream client signals a need. Pull tin operate alongside single
units or minor batches. It enables production without preset schedules.
checklists, worksheets, diagrams, expanse maps, etc., as well as may pertain to equipment use, operations,
processes, metrics, storage, safety, quality, motion inward an area, or full general usage of the environment.
Setup Reduction (Single Minute Exchange of Dies or SMED)
SMED is a serial of operator techniques pioneered past times Shigeo Shingo that termination inward changeovers of
production mechanism inward less than 10 minutes. The long-term objective is ever null setup, in
which changeovers are instantaneous as well as practise non interfere inward whatever way alongside one-piece flow.
Poka-yoke (Mistake Proofing)
Japanese term used past times Shigeo Shingo to hateful "innocent mistake-proofing," it is an improvement
applied scientific discipline that uses a device or physical care for to foreclose defects or equipment malfunction during
order-taking or manufacture. Mistake proofing devices are of import to the production business in
several ways:
(1) enforce right operations past times eliminating choices that Pb to wrong actions,
(2) signal or halt a physical care for if an error is made or a defect created
(3) foreclose machine as well as production damage.
5S
Five south (5S) an improvement process, originally summarized past times 5 Japanese words beginning
alongside S, to create a workplace that volition run into the criteria of visual command as well as lean production. Seiri
(sort) agency to split upwards needed tools, parts, as well as instructions from the unneeded as well as to remove
the latter. Seiton (set inward order) agency to neatly conform as well as position parts as well as tools for ease of use.
Seiso (shine) agency to create clean as well as inspect. Seiketsu (standardize) agency to require every bit the norm that
everyone sort, laid inward order, as well as shine at frequent (daily) intervals to maintain the workplace inward perfect
condition, as well as also to brand usage of visual command systems. Shitsuke (sustain) agency to maintain the
5 south gains past times preparation as well as encouraging workers to cast the habit of ever next the first
4 Ss.
SEVEN QC TOOLS:
5S
Five south (5S) an improvement process, originally summarized past times 5 Japanese words beginning
alongside S, to create a workplace that volition run into the criteria of visual command as well as lean production. Seiri
(sort) agency to split upwards needed tools, parts, as well as instructions from the unneeded as well as to remove
the latter. Seiton (set inward order) agency to neatly conform as well as position parts as well as tools for ease of use.
Seiso (shine) agency to create clean as well as inspect. Seiketsu (standardize) agency to require every bit the norm that
everyone sort, laid inward order, as well as shine at frequent (daily) intervals to maintain the workplace inward perfect
condition, as well as also to brand usage of visual command systems. Shitsuke (sustain) agency to maintain the
5 south gains past times preparation as well as encouraging workers to cast the habit of ever next the first
4 Ss.
SEVEN QC TOOLS:
- Check canvass or tally sheet
- Histogram
- Pareto chart
- Cause as well as outcome diagram
- Process menses chart
- Control chart
- Scatter diagram
JIT (JUST IN TIME):
Just inward fourth dimension (JIT) is a production strategy that strives to meliorate a concern provide on investment past times reducing in-process inventory as well as associated carrying costs. To run into JIT objectives, the physical care for relies on signals or Kanban betwixt dissimilar points inward the process, which say production when to brand the side past times side part. Kanban are usually 'tickets' but tin last uncomplicated visual signals, such every bit the presence or absence of a component on a shelf. Implemented correctly, JIT focuses on continuous improvement as well as tin meliorate a manufacturing organization's provide on investment, quality, as well as efficiency. To attain continuous improvement primal areas of focus could last flow, employee interest as well as quality.
KANBAN TOOLING:
Kanban is i of most pop tools inward lean manufacturing. This is a uncomplicated concept, but rattling effective. Kanban mainly focus on the reduction of overproduction. There are mainly 2 types of kanbans. They are
Kanban is i of most pop tools inward lean manufacturing. This is a uncomplicated concept, but rattling effective. Kanban mainly focus on the reduction of overproduction. There are mainly 2 types of kanbans. They are
- Withdrawal kanban
- Production kanban
BENEFITS OF LEAN MANUFACTURING
The implementation of lean manufacturing through trying to brand value menses at the line of the client (Just In Time) prevents as well as eliminates waste materials inward your processes. Waste beingness categorized every bit component of the 7 wastes: Transport, Inventory, Motion, Waiting, Over-processing, Overproduction, as well as Defects.
Many studies receive got shown that nosotros exclusively add together value for unopen to 5% of the fourth dimension inside our operations, the remaining 95% is waste! Imagine if y'all could take that 95% wasted fourth dimension as well as effort; what would it practise for your operations?
- Typically Lean volition improve;
- Quality performance, fewer defects as well as rework (in theatre as well as at customer).
- Fewer Machine as well as Process Breakdowns.
- Lower levels of Inventory.
- Greater levels of Stock Turnover.
- Less Space Required.
- Higher efficiencies, to a greater extent than output per human hour.
- Improved delivery performance.
- Faster Development.
- Greater Customer Satisfaction.
- Improved employee morale as well as involvement.
- Improved Supplier Relations.
- HIGHER PROFITS!
- INCREASED BUSINESS