Lean Manufacturing Principles Overview
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Lecture 1: Overview
Lecture 1: Overview
1.
Course goals and syllabus
Course goals and syllabus
2.
Logbook expectations & logbook review form
Logbook expectations & logbook review form
3.
Mass Production vs Lean Enterprise Systems
Mass Production vs Lean Enterprise Systems
4.
Lean Manufacturing overview
Lean Manufacturing overview
5.
Plant layout models.
Plant layout models.
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Mass Production System
Mass Production System
* Example: Ford
* Example: Ford
* Status as of 1950
* Status as of 1950
8000/day
8000/day
Low-skilled immigrant labor
Low-skilled immigrant labor
Vertical integration
Vertical integration
Abundant investment capital
Abundant investment capital
* High volume, low mix
* High volume, low mix
* Capital, Quantity, Repeatability
* Capital, Quantity, Repeatability
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Lean Enterprise System
Lean Enterprise System
* Example: Toyota
* Example: Toyota
* Status as of 1950
* Status as of 1950
2500/year
2500/year
Diversified market
Diversified market
Limited capital
Limited capital
Dedicated, high skilled labor
Dedicated, high skilled labor
* Low volume, high mix
* Low volume, high mix
* People, Quality, Flexibility
* People, Quality, Flexibility
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Definition of Lean
Definition of Lean
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Concept of Value-Added Activity
Concept of Value-Added Activity
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Common Manufacturing Terms:
Common Manufacturing Terms:
Batches
Batches
Order of Operations
Order of Operations
Inventory
Inventory
Work in Progress (WIP)
Work in Progress (WIP)
Fixturing
Fixturing
Set-Up Time
Set-Up Time
Inspection
Inspection
Plant Layout
Plant Layout
Manufacturing Lead Time (MLT)
Manufacturing Lead Time (MLT)
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Process Layout – small shop
Process Layout – small shop
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Process Layout - factory
Process Layout - factory
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Product Layout
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Products typically ride along
on conveyor belts or chains.
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parallel lines of processes
combining at one node.
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Fixed Position Layout
Fixed Position Layout
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Cellular Layout
Cellular Layout
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Lean Building Blocks
Lean Building Blocks
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Analyze the core concepts of Lean Manufacturing in a systematic approach to eliminate waste and enhance operational efficiency. Explore the contrast between Mass Production and Lean Enterprise Systems, emphasizing value-added activities, common manufacturing terms, and plant layout models for Lean implementation.
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Presentation Transcript
Lecture 1: Overview 1. Course goals and syllabus 2. Logbook expectations & logbook review form 3. Mass Production vs Lean Enterprise Systems 4. Lean Manufacturing overview 5. Plant layout models. Principles for Implementing Lean Manufacturing
Mass Production System * Example: Ford * Status as of 1950 8000/day Low-skilled immigrant labor Vertical integration Abundant investment capital * High volume, low mix * Capital, Quantity, Repeatability Principles for Implementing Lean Manufacturing
Lean Enterprise System * Example: Toyota * Status as of 1950 2500/year Diversified market Limited capital Dedicated, high skilled labor * Low volume, high mix * People, Quality, Flexibility Principles for Implementing Lean Manufacturing
Definition of Lean A systematic approach to identifying and eliminating waste (non-value-added activities) in a company s operations. Lean emphasizes flowing the product at the pull of the customer. Lean is implemented through both rapid andcontinuous improvement. Kaizen- kai means little or ongoing . Zen means for the better or good. Small continuous improvements on everyone s part leads to world class manufacturing. Principles for Implementing Lean Manufacturing
Concept of Value-Added Activity Value-Added Time Any activity that increases the market form or function of the product or service. (These are things the customer is willing to pay for.) Non-Value Added Time (Waste or muda) Any activity or use of resources that does not add market form or function or is not necessary. (These activities should be reduced, integrated, simplified, or eliminated.) Principles for Implementing Lean Manufacturing
Common Manufacturing Terms: Batches Order of Operations Inventory Work in Progress (WIP) Fixturing Set-Up Time Inspection Plant Layout Manufacturing Lead Time (MLT) Principles for Implementing Lean Manufacturing
Process Layout small shop Principles for Implementing Lean Manufacturing
Process Layout - factory Ship QC Rec Raw Stock QC Screw Machine Shear Stamp Lathe Drill Assembly Brake Mill Weld Grind Finish Parts Stock Principles for Implementing Lean Manufacturing
Product Layout Products typically ride along on conveyor belts or chains. This layout may have several parallel lines of processes combining at one node. This arrangement is relatively inflexible compared to a Process Layout. Principles for Implementing Lean Manufacturing
Fixed Position Layout In this layout, the product s position is fixed due to its size or weights such as a jetliner. Equipment, components, and labor is brought to the product for the operations. When the product is complete, it is then moved. The moving assembly line used to build the market-leading Boeing 777 photo (Neg#: K63841-01) Principles for Implementing Lean Manufacturing
Cellular Layout Linking of manual and machine operations into the most efficient combination to maximize value-added content while minimizing waste. Punch De-burr Cut to size Package Form Sand Principles for Implementing Lean Manufacturing
Lean = Eliminating Waste Non-Value-Added: Hold all waste in a CLOSED MITT Value-Added Complexity Labor Overproduction Space Energy Defects Materials Idle Materials Transportation Time Typically 95% of all lead time is non-value-added Principles for Implementing Lean Manufacturing
Lean Building Blocks KAIZEN Pull/Kanban Cellular/Flow TPM Quality at Source POUS Quick Changeover Standardized Work Batch Reduction Teams Value Stream Mapping 5S System Visual Plant Layout Principles for Implementing Lean Manufacturing
