Chapter 11

• Lean techniques: improving process efficiency

Group members
• Muhammad Irfan
• Muhammad Zulqarnain
• Fakhar Ilyas
• Muhammad Waqas
Lean Introduction
• Lean means creating more values for customer with fewer resources .The emphasis is on
eliminating non-value add activities such as late services, defective products etc. Lean means
creating more values for customer with fewer resources .
• War man power commission is famous for its focus on reducing the original Toyota seven
deadly wastes: overproduction , wait time, transportation ,processing method, inventory ,
motion and defects in order to improve the overall customer satisfaction . These are waste of
people unused creativity.
Lean in Non-manufacturing –Based
industries
• Lean is also used in non manufacturing based industries to reduce waste
in hospitals, insurance , companies , financial services .
Relationship of lean to managing
quality
• Lean management is a quality management tool for making business operations
more efficient. It is focused on a process of continuous improvement that uses
statistical methods to reduce the number of defects found in operational processes
• Designing for is similar to designing for quality
 Eight wastes
1.overproduction-making or doing more than is required or earlier needed
2.Waiting – for information ,material, people, and maintenance
3.Transport-moving people or goods between sites
4.Poor process design –too many/too few steps , no standardization ,and inspection
rather than prevention
5.Inventory-raw materials, work in process, fi and finished goods, papers ,and
electronic
6.Motion – inefficient layouts at workstation , in office, poor ergonomics
7.Defects - error, scrap, rework, nonconformance
8.Underutilized personnel resources and creativity – ideas that are not listened, skills
that are not used
Organizations wants to be lean:
• The Lean mission is to have the –
• shortest possible lead time
• optimum level of strategic inventory
• highest practical customer order service
• highest possible quality (low defect rate)
• lowest possible waste (low COPQ)
RIE & Kaizen
• Kaizen is a japnese word For incremental improvement
• They are typically one-week focused efforts that are facilitated and conducted by
lean experts or black belts to enable the lean teams to analyze the value stream and
quickly develop/Implement solutions in a short time-frame.
What do RIE do?
• Describe the current state
• Identify gaps and problems (wastes)
• Brainstorm solutions
• Define the future state
• Implement as much as possible and develop a plan for remaining open items.
Inventory Analysis:
• Inventory analysis is the process of understanding the stock/product mix
combined with the knowledge of the demand for stock/product. It is the
technique to determine the optimum level of inventory for a firm.
Little’s Law:
Managing and Eliminating
Constraints:
• Identifying the constraint
• Deciding how to exploit the constraint
• Subordinating all else to the above decision
• Elevating the performance of the constraint
• Moving to the next constraint and go back to setup 1
Improving the Process and Implementing Pull
System:
• The steps for improvement teams to lean out an operation are as follows:

1.Determining the place (take time , manpower)

2.Establishing sequence (turnover, changeover required)
3.Designing the line or process (sequence)
4.Feeding the line or process (inventory , standard WIP)
5.Balancing the line or process (standard work)
6.Stabilizing and refining (continuous improvement)
Physical Design and Proximity:
• Lean manufacturing is 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.

Kanban: Signal to Produce

• Kanban helps your team analyze the system and make adjustments to
improve flow so as to reduce the time it takes to complete each piece of
work.
• Kanban is a scheduling system that is used in lean processes and Just-In-
Time inventory replenishment programs to help companies improve their
production and reduce their overall inventory
Reliability and maximizing equipment
performance :
• Reliability is the ability to supply a product or service on or before it is
promised. Within operations , this normally directly ties to a resource being
able to consistently produce the quantity and quality demanded by the
customer.
Total productive maintenance(TPM)
TPM (Total Productive Maintenance) is a holistic approach to equipment
maintenance that strives to achieve perfect production:
• No Breakdowns
• No Small Stops or Slow Running
• No Defects
In addition it values a safe working environment:
• No Accidents
What is RCM?
Definition : Reliability-centered maintenance (RCM) is a corporate-level maintenance
strategy that is implemented to optimize the maintenance program of a company or
facility.
The maintenance strategies are optimized so that the productivity of the plant is
maintained using cost-effective maintenance techniques.
There are four principles that are critical for a
reliability-centered maintenance program:
• The primary objective is to preserve system function
• Identify failure modes that can affect the system function
• Prioritize the failure modes
• Select applicable and effective tasks to control the failure modes
Mistake proofing the process :

An important element of prevention is designing the process to be error free

through “mistake proofing “ .
A widely used form of mistake proofing is the design ( or redesign of the machines
and tools , the hardware ) to make human error improbable or even impossible.
Thank you