Lean PPT-2

1. Lean PPT-2 <a rel="license" href="http://creativecommons.org/licenses/by/4.0/"><img alt="Creative Commons License" style="border-width:0" src="https://i.creativecommons.org/l/by/4.0/88x31.png" /></a><br /><span xmlns:dct="http://purl.org/dc/terms/" property="dct:title">Lean PPT-2</span> by <span xmlns:cc="http://creativecommons.org/ns#" property="cc:attributionName">Dr.R.Gnanaguru</span> is licensed under a <a rel="license" href="http://creativecommons.org/licenses/by/4.0/">Creative Commons Attribution 4.0 International License</a>.

2. Lean Manufacturing Dr.R.G. Unit II Lean Tools and Methodologies Problem solving tools – Cause and Effect Diagram, Pareto analysis, FMEA, Work cell and equipment management tools – Process Mapping, Spaghetti diagram, U shaped Layout, Poke Yoke, Kanban, Andon, SMED, One Piece Flow, GenechiGenbutsu, Milk run, Visual work place, Quality at the source Methodologies – Pillars of Lean Manufacturing – Just in Time, Jidoka, 5S, TPM, Six Sigma, DFMA, Kaizen.

3. Lean Manufacturing Dr.R.G. 2.1. PROBLEM SOLVING TOOLS

4. Lean Manufacturing Dr.R.G. 2.2.CAUSE AND EFFECT DIAGRAM

5. Lean Manufacturing Dr.R.G. Procedure to create Cause and Effect diagram:

6. Lean Manufacturing Dr.R.G.

7. Lean Manufacturing Dr.R.G. 2.3. PARETO ANALYSIS

8. Lean Manufacturing Dr.R.G. 2.4. FMEA (Failure modes and effects analysis )

9. Lean Manufacturing Dr.R.G. 2.5. WORK CELL

10. Lean Manufacturing Dr.R.G. 2.6.EQUIPMENT TOOLS MANAGEMENT • It's reusable as is - return it to a storage location. • It needs reconditioning, so send it out for repair or re-sharpen it. • It is un-repairable - discard it.

11. Lean Manufacturing Dr.R.G. • Tool issue tracking by employee, date, job and profit center/machine. • Support transactions. • Ease of use. • Tool storage stations. • Process new and regrind tool activities. • Tool tracking cross-reference. • Tool availability. • Status reports. • Ordering reports. • Basic inventory information reports. • History information. Basic Features for Tool Management • Tool/part number. • Description. • Price. • Quantity requirements. • Where used by shop floor, machines, jobs and users. • Minimum/maximum inventory levels. • Reorder point. • Vendor information. • Lead times. • Custom and standard reports.

12. Lean Manufacturing Dr.R.G. 2.7. PROCESS MAPPING

13. Lean Manufacturing Dr.R.G. • Benefits of process mapping: • Process mapping spotlights waste, streamlines work processes and builds understanding. Process mapping allows you to visually communicate the important details of a process rather than writing extensive directions. • Increase understanding of a process • Analyze how a process could be improved • Show others how a process is done • Improve communication between individuals engaged in the same process • Provide process documentation • Plan projects

14. Lean Manufacturing Dr.R.G. Process mapping symbols:

15. Lean Manufacturing Dr.R.G. 2.8. SPAGHETTI DIAGRAM

16. Lean Manufacturing Dr.R.G. SPAGHETTI DIAGRAM

17. Lean Manufacturing Dr.R.G. 2.10. POKE YOKE

18. Lean Manufacturing Dr.R.G. • To overcome the inefficiencies of inspection through the use of automatic devices called Poka Yoke, these seek to do three things; • Not accept a defect for the process • Not Create a Defect • Not Allow a Defect to be passed to the next process • POKA YOKE CAN BE CATEGORIZED AS: • Control – they take physical action to prevent a defect • Warning – They sound an alarm or light up to tell us a mistake has been made.

19. Motion Stop Poka Yoke Lean Manufacturing Dr.R.G. Types of Poka Yoke: Contact Poka Yoke Fixed Value Poka Yoke Motion Stop Poka Yoke

20. Lean Manufacturing Dr.R.G. 2.11.KANBAN

21. Lean Manufacturing Dr.R.G. 2.12. ANDON

22. Lean Manufacturing Dr.R.G. 2.13. SMED (Single-Minute Exchange of Die )

23. Lean Manufacturing Dr.R.G.

24. Lean Manufacturing Dr.R.G. 2.14. ONE PIECE FLOW

25. Lean Manufacturing Dr.R.G. 2.15. GENCHI GEMBUTSU “go and see for yourself”

26. Lean Manufacturing Dr.R.G. 2.16. MILK RUN

27. Lean Manufacturing Dr.R.G. 2.17.VISUAL WORK PLACE

28. Lean Manufacturing Dr.R.G.

29. Lean Manufacturing Dr.R.G. 2.19. PILLARS OF LEAN MANUFACTURING

30. Lean Manufacturing Dr.R.G. 2.20. JUST IN TIME • JIT aims to achieve the following objectives: • Zero inventory • Zero breakdowns • 100% on time delivery • Elimination of Non value added activities • Zero defects.

31. Lean Manufacturing Dr.R.G.

32. Lean Manufacturing Dr.R.G. 2.21.  JIDOKA Jidoka is about quality at source, or built in quality • Jidoka principles: • Discover an abnormality • STOP • Fix the immediate problem • Investigate and correct root cause

33. Lean Manufacturing Dr.R.G. 2.22. 5-S

34. Lean Manufacturing Dr.R.G. 2.23. TPM (Total Productive Maintenance )

35. Lean Manufacturing Dr.R.G.

36. Lean Manufacturing Dr.R.G. 2.24. SIX SIGMA The DMAIC project methodology has five phases: The DMADV project methodology, known as DFSS ("Design For Six Sigma“):

37. Lean Manufacturing Dr.R.G. DFMA stands for Design for Manufacture and Assembly.

38. Lean Manufacturing Dr.R.G. PRINCIPLES IN DESIGN FOR MANUFACTURING AND ASSEMBLY: 1. Minimize number of components. 2. Use standard commercially available components. 3. Use common parts across product lines. 4. Design for ease of part fabrication. 5. Design parts with tolerances that are within process capability. 6. Design the product to be foolproof during assembly. 7. Minimize use of flexible components. 8. Design for ease of assembly. 9. Use modular design. 10. Shape parts and products for ease of packaging. 11. Eliminate or reduce adjustment required.

39. Lean Manufacturing Dr.R.G. 2.26. KAIZEN

40. Lean Manufacturing Dr.R.G. • Additional Topics: • Shadow boards • Clock chart

41. Lean Manufacturing Dr.R.G. • Shadow boards

42. Lean Manufacturing Dr.R.G. • Shadow boards

43. Lean Manufacturing Dr.R.G. • Clock chart

44. Lean Manufacturing Dr.R.G. Assignment – 2 : Prepare a Shadow board using thermocool for keeping the following item: 1.Pen, 2.Pencil, 3.Eraser, 4.Sharpener, 5.Scale, 6.Marker pen, 7.Sketch pen, 8. Cello tape, etc.,