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LEAN SYSTEMS

LEAN SYSTEMS. Lean systems are operation’s systems that maximize the value added by each of a company’s activities by pairing unnecessary resources & delays from them

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LEAN SYSTEMS

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  1. WWW.PPTMART.COM

  2. LEAN SYSTEMS WWW.PPTMART.COM

  3. Lean systems are operation’s systems that maximize the value added by each of a company’s activities by pairing unnecessary resources & delays from them • Lean implementation is therefore focused on getting the right things to the right place at the right time in the right quantity to achieve perfect work flow, while minimizing waste and being flexible and able to change. WWW.PPTMART.COM

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  5. BENEFITS OF LEAN SYSTEMS • It cut cycle time • It improve inventory turnover • It increases labor productivity • It reduces cost • It improves efficiency • It increases production capacity • It reduces waste WWW.PPTMART.COM

  6. TECHNIQUES OF LEAN SYSTEMS • QUALITY AT THE SOURCE • SMALL LOT SIZES • CLOSE SUPPLIER TIES • PULL METHOD OF WORK FLOW • UNIFORM WORKSTATION LOADS • STANDARDIZED COMPONENTS AND WORK METHODS • FLEXIBLE WORK FORCE • LINE FLOWS • AUTOMATION • FIVE S (5S) • PREVENTIVE MAINTENANCE WWW.PPTMART.COM

  7. QUALITY AT THE SOURCE • In this the organization efforts to improve the quality of a firms products by having employees act as their own quality inspector. • One approach for implementing quality at source is to use POKA-YOKE ( mistake proofing methods ) aimed at designing fail-safe systems that attack and minimize human error. eg : Shipping boxes WWW.PPTMART.COM

  8. SMALL LOT SIZES • A lot is a quantity of items that are processed together . • Small lots pass through the system faster than large lots • Small lots are easier to manage if any defective items are discovered . • Small lots helps in achieve a uniform workload on the system. WWW.PPTMART.COM

  9. CLOSE SUPPLIER TIES • Lean systems operate with low levels of inventory therefore firms need to have close relationships with their suppliers. - generally utilizes local suppliers - pare down the number of suppliers - cooperative orientation with suppliers WWW.PPTMART.COM

  10. PULL AND PUSH METHOD OF WORK FLOW • PUSH METHOD: A method in which production of the item begins in advance of customer needs. • PULL METHOD: A method in which customer demand activates production of the service or item. eg : Cafeteria WWW.PPTMART.COM

  11. UNIFORM WORKSTATION LOADS • Lean system works best if the daily load on individual workstations is relatively uniform. • Service processes can achieve workstations load by using RESERVATION SYSTEMS. • Manufacturing processes can achieve uniform workstation load by assembling the same type and number of units each day. ( mixed model assembly ) e.g : Hospitals ( scheduled surgeries in advance) Toyota :200 Camry (C) ,150 Avalon (A) , 100 Sienna (S) 4Cs , 3As ,2Ss C-S-C-A-C-A-C-S-A WWW.PPTMART.COM

  12. STANDARDIZED COMPONENTS AND WORK METHODS • Work method should be monitored and revised in order to improve service • In manufacturing , standardization of components ( part commonality or modularity) increases repeatability. • It helps in achieving high-productivity, low-inventory. WWW.PPTMART.COM

  13. FLEXIBLE WORKFORCE • Ability to shift workers among workstations to help relieve bottlenecks . • Workers can step in and do the job for those who are on leave • For customized services or product , firm’s need multi skilled workforce WWW.PPTMART.COM

  14. LINE FLOWS • Line flows is a technique in which employees and equipments are organized to provide uniform workflows through the process • Line flows can reduce the frequency of setups • Group technology - design small production lines that manufacture in volume , families of components with common attributes • One Worker Multiple Machines( OWMM) – one worker operates several machines WWW.PPTMART.COM

  15. AUTOMATION • Automation is a key to low cost operation • Helps in earning greater profits ( because prices can be cut ) • It reduces cost e.g. : banks - ATMs WWW.PPTMART.COM

  16. FIVE S • It is a methodology for organizing , cleaning , developing and sustaining a productive work environment. • These 5 practices are : - sorting ( separate needed from unneeded items) - straightening (neatly arrange what is left) - shining ( clean and wash the work area & make it shine) - standardizing ( regularly doing the first 3 S practices) - sustaining ( create discipline to perform the first 4 S practices) WWW.PPTMART.COM

  17. KANBAN SYSTEM • Cards used to control the flow of production through a factory . WWW.PPTMART.COM

  18. VALUE STREAM MAPPING A qualitative lean tool for eliminating waste that involves a current state drawing , a future state drawing and an implementation plan. It spans the entire value chain from the firms receipt of raw materials to the delivery of finished goods to the customers WWW.PPTMART.COM

  19. JIT II • The supplier is brought into the plant to be an active member of the purchasing office of the customer. • The in plant representative is on site full time at the suppliers expense and is empowered to plan and schedule the replenishment of materials from the suppliers. WWW.PPTMART.COM

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