Yaa A Comprehensive Written Report On Thin Manufacturing Process

A Comprehensive Study on Lean Manufacturing Process

Md.Tanvirul Haque Bhuiyan
Dept. of Apparel Manufacturing,
National Institute of Textile Engineering & Research (NITER), Savar, Dhaka.
Email : mukutex@gmail.com
Facebook : Tanvirul Haque Mukut

Lean Manufacturing:
Lean Manufacturing – Influenza A virus subtype H5N1 way to eliminate waste materials as well as meliorate efficiency inward a manufacturing environment. Lean focuses on flow, the value current as well as eliminating ‘muda’, the Japanese give-and-take for waste. Lean manufacturing is the production of goods using less of everything compared to traditional volume production: less waste, human effort, manufacturing space, investment inward tools, inventory, as well as applied scientific discipline fourth dimension to educate a novel product. Lean is the systematic approach to identifying as well as eliminating waste materials through continuous improvement past times flowing the production or service at the push clit of your client inward pursuit of perfection.

Origin:
During II the world war, the economical status of Nippon was heavily destroyed. They had express infrastructure, inventories, machine & materials. So they decided to create a little batch of products which would cut down inventories; it agency they would involve less working capital missive of the alphabet to create the same product. Lean manufacturing is a management philosophy derived generally from the Toyota Production System(TPS) because Toyota Motor Company’s Eiji Toyoda as well as Taiichui Ohno are given credit for its approach as well as innovations, this organization identified every bit "lean" alone inward the 1990s.

Procreation:
Lean was generated from the Just-in-time (JIT) philosophy of continuous as well as forced work solving Just-in-time is supplying customers amongst precisely what they desire when they desire it With JIT, supplies as well as components are “pulled” through a organization to become far where they are needed when they are needed. Just inward fourth dimension (JIT) is a production strategy that strives to meliorate a business' render on investment past times reducing in-process inventory as well as associated carrying costs. Just inward fourth dimension is a type of operations management approach which originated inward Nippon inward the 1950s. It was adopted past times Toyota as well as other Japanese manufacturing firms, amongst first-class results: Toyota as well as other companies that adopted the approach ended upwardly raising productivity significantly.

Areas of Lean:

Quality- Increasing quality.
Cost- Reducing cost.
Productivity- Increasing productivity.
Safety as well as morale- Ensuring safety.

Waste elimination:
Waste is anything that happens to a production that does non add together value from the customer’s perspective. Products existence stored, inspected or delayed, products waiting inward queues, as well as defective products attain non add together value. There are 7 major types of waste materials –

Overproduction – Producing to a greater extent than than the client orders or producing besides early. Inventory of whatever sort is unremarkably wastage. TPS pays item attending to the waste materials of overproduction.

Queues – Time is a express resource. In the manufacturing world, fourth dimension is money. Customer requirements are calculated to the second. Idle time, storage, as well as waiting are wastes.

Transportation – Moving fabric betwixt plants, betwixt operate centers, as well as treatment to a greater extent than than 1 time is waste.

Inventory – Preventing unnecessary inventory is critical to the success of the Toyota Production System. The smooth, continuous menses of operate through each procedure ensures that excess amounts of inventory are minimized unnecessary raw material, work-in procedure (WIP), finished goods, as well as excess operating supplies are wastes.

Motion –Motion is the motion of equipment or people. Wasted displace occupies fourth dimension as well as energy. Ideally all unnecessary movements or actions are eliminated from the operate process.

Over-processing – It refers to the works performed on production that adds no value. Over processing is every bit wasteful every bit insufficient processing. Employees must larn to position over processing waste.

Defective product – The waste materials of correction is a consequence of misfortunate internal quality. Producing defective products or products requiring repairs adds the toll of extra manpower, materials, facilities as well as conveyance measures.

Advantages of Lean Manufacturing:

Increased overall productivity.
Reduced sum of flooring infinite required for production.
Reduced manufacturing atomic number 82 time.
Improved flexibility to react to changes inward production flow.
Improved character of the product.

Disadvantages of Lean Manufacturing:

Difficulty involved amongst changing processes to implement lean principals.
Long term commitment required for permanent change.
Very risky procedure inward illustration of furnish chain issues piece changing over to lean.

House of Lean:
As a draw concern philosophy, Lean tin endure envisioned every bit a house. The House of Lean is formed past times a foundation (Stability), 2 pillars (Just inward Time as well as Jidoka), as well as a roof (Perfection). Many of the tactical components of Lean select been placed inside these dissever areas to give you lot a convenient frame of reference as well as an agreement of where for certain tools autumn inside the vast arena of Lean.

House of Lean

Role of Lean for Producers:

Role of Lean for Customers:

Lean Manufacturing Tools:
Lean manufacturing inward a mill is maintained past times several tools. The number as well as type of tool depends on the production that is to endure produced as well as production organization of the product. Most of import tools are –