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Lean Manufacturing

Kaizen Institute India shared the latest development & trends related to Operational Excellence at this conclave - Kaizen incorporates a variety of techniques and principles into the overall culture and philosophy of improvement–improvement as a way of life, rather than the application of isolated techniques.

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Lean Manufacturing

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  1. LEAN MANUFACTURING COMPETITIVENESS PROGRAMME

  2. It is the production of goods, using less of everything, i.e; - less human effort - less manufacturing space - less investment in tools - less engineering time etc. It is a business initiative to reduce “waste” in manufactured products. Lean is one of the latest management tools in cost reduction . WHAT IS LEAN MANUFACTURING ?

  3. Itreduces cost by: Improving labour use. Decreasing inventories. Reducing manufacturing order to shipment cycle time. Increasing capacities, without substantial capital inputs HOW DOES LEAN MANUFACTURING WORK ?

  4. Helps firms produce more with the same resources by eliminating the non-value added activities. Applies simple techniques to identify / eliminate the wastage and streamline systems. Focuses on improving the entire process flow. Emphasizes worker empowerment throughout [“Decent Work”] WHAT DOES LEAN MANUFACTURING DO ?

  5. 5S System Visual Control Standard Operation Procedures (SOPs) Just in Time (JIT) KANBAN System Cellular Layout Value Stream Mapping POKA YOKEor Mistake Proofing SMED (Single Minutes Exchange of Dies or Quick Changeover) TPM (Total Productive Maintenance) KAIZEN BLITZ-Rapid Improvement Process TECHNIQUES OF LEAN MANUFACTURING

  6. DELIVERABLES • Unit level Deliverables: • - Reduction of Costs. • - Reduction of Cycle Time. • - Lowering of Defects / Rework Cost. • - Reduction of System related Wastes.

  7. Expected “externals”: - Skill up-gradation of Labour. - Improvement of Techniques. - Increase in Labour Productivity. - Lowering in-put cost of other industries. - Introducing of new production equipments / methods. - Betterment of work culture in society. - Development of a large pool of Lean Consultants. - Trigger competitiveness as a chain reaction. - Build a strong structure in private sector to sustain continuity of market driven requirements. DELIVERABLES (Contd…)

  8. Industries’ norm for wastage = - Developed countries 10 - 20 % of turnover. - Developing countries 20 – 30 % of turnover. RETURN ON INVESTMENT [ROI]

  9. ® KAIZEN Management System

  10. Thank you!  KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE Ltd.

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