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IENG 451

IENG 451. Lean Production System. Lean Production. Do it better, do it faster, do it cheaper Old System Price = cost + profit New System Price (fixed) – cost = profit Key to Profitability is to cost reduction Key to cost reduction is employee involvement. Systems .

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IENG 451

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  1. IENG 451 Lean Production System

  2. Lean Production • Do it better, do it faster, do it cheaper • Old System • Price = cost + profit • New System • Price (fixed) – cost = profit • Key to Profitability is to cost reduction • Key to cost reduction is employee involvement

  3. Systems • A system is an integrated series of parts working together to achieve a goal • Consider the best of the best

  4. System Mental Model Conventional Model Lean Model Stop production so that production never has to stop Make only what the customer wants (pull) Small batches People closest to work make standards Make problems visible • Move the material • Make as much as you can (push) • Large batches • Engineers/managers make standards

  5. Lean Gurus • Ohno – conceived Toyota lean production system • Hiroyuki Hirano – 5S system • Seiichi Makajima – total productive maintenance • Kenichi Sekine – continuous flow • Shigeo Shingo – jidoka, single-minute exchange of dies (SMED)

  6. Lean System Goal Customer Focus High quality, low cost, short lead time Just-in-time Jidoka Employee Involvement Standardization Stability

  7. Muda • Waste or any activity consumers are not willing to pay • Human motion • Actual work • Auxiliary work • Muda

  8. Forms of Muda • Delay – waiting for parts, waiting for a machine, waiting for operator • Conveyance – large scale waste caused by inefficient layout, making large batches • Correction – making and having to fix defective parts • Over processing – design requirements that have little to do with customer desires; Porsche, NISH

  9. Forms of Muda • Inventory – carrying excess WIP, usually happens in a push system such as MRP • Over production – making things that don’t sell; e.g.; big belt buckles, Ertl toys • Knowledge Disconnection – disconnects within a company or between a company and a supplier; disconnects at SDSMT?

  10. Muda Lengthens Throughput Time Motion Disconnects Waiting Inventory Over Production Conveyance Over Processing Correction

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