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[Audio] Good morning everyone and welcome to our presentation on lean manufacturing. Lean manufacturing is an increasingly popular system for optimizing production flow and efficiency, and today we'll be exploring the fundamentals of this system, from its history to its current applications. We'll also discuss how lean manufacturing can help define value from the customer's perspective. So let's get started..

[Audio] Manufacturing has seen various developments since its inception in the early days of craft production. Craft production resulted in unique products but often at a hefty cost. The industrial revolution brought forth mass production, thanks to interchangeable parts innovated by Eli Whitney. Subsequently, division of labor, with Frederick Taylor as its conceptualizer, allowed for assembly lines and flow variety, a concept which Henry Ford excellently executed. In recent times, Lean manufacturing has further advanced manufacturing, offering high variety in production with small batches and excellent Six Sigma quality..

[Audio] LEAN manufacturing is an approach to manufacturing based on eliminating any unnecessary activities or steps in the production process. It focuses on delivering quality products or services on time, connecting value-adding activities in a continuous sequence. A small fraction of total time and effort in an organization is allocated to adding value for the end customer..

[Audio] Slide we are discussing is about the significance of Lean Manufacturing. In an extremely competitive market, firms need to reduce their margins to remain competitive and increase their profit margins. To achieve this, it is essential to ensure that every available resource is used efficiently and the cost of operations is kept low. Lean Manufacturing is a method that meets these objectives. It works by reducing activities involved in production and services - both value-adding and non-value-adding. This method ensures that resources are used effectively and cost of production is kept to a minimum..

[Audio] Misconceptions about Lean Manufacturing are widespread. People may think it only applies to manufacturing plants, won't work in their business, or is a new version of Kaizen Events. Similarly, 5S is often misunderstood as being just about cleaning office or workstations, that it can't apply to their business, that it will lead to job losses, or that it means zero inventory. In this discussion, we will be looking at these and other myths and misconceptions..

[Audio] Lean Manufacturing seeks to increase efficiency, reduce waste, and improve customer value by concentrating on value adding activities (VAM). This can lead to impressive gains including a 15% growth within a year, a 12% rise in productivity, 20% space saving, 90% on-time delivery, and 28% cut in throughput times. Moreover, it can also result in better supplier performance and improved customer satisfaction through higher quality. All this can be achieved by progressively eliminating non-value adding activities (MUDA)..

[Audio] Lean System allows for companies to customize structures that best meet their goals by assigning roles and responsibilities. Developing a process-driven culture, Lean System provides visual evidence of goals met and rewards employees with greater capabilities and morale. Additionally, visual indicators can be used to discover and address any atypical scenarios. Furthermore, Lean System grants the ability to effectively use resources with the likelihood of higher return on investment and improved predictions of outcomes..

[Audio] LEAN manufacturing aims to reduce waste and increase efficiency. It requires identifying all the steps of the value stream, creating a system that allows these processes to flow when the customer requires them, and involving and empowering employees to create the desired value. It additionally focuses on continually eliminating successive layers of waste, striving for perfection..

[Audio] Using Quality Function Deployment and the KANO model to analyze customer requirements helps determine the true value of Lean manufacturing. This ensures the best possible outcome in terms of quantity, quality and timing. Applying these analytical models allows for the production of products and services at the lowest cost with the highest quality possible..

KANO Model • Classify Characteristics as Basic, performance and delighter • Ask two questions 1. What if the characteristics is present? 2. What if the characteristics is absent? If I-neutral, & 2=bad it is basic • If I-good & 2=neutral, it is delighter.

[Audio] Defining values our customer has in mind and assessing their response time expectations are essential in order to maximize value while minimizing resource waste with Lean Manufacturing. We must evaluate the product or service provided, what features and attributes the customer is expecting, what quality level is necessary, and what delivery rate will be needed to ensure best results. All of these values must be measured correctly for Lean Manufacturing to be effective..

[Audio] Value streams are essential in the process of creating a product or service, and a value stream map is the visual outline of this series of steps. The tools used to create this map are pencil, paper, post-its and more, all of which help to identify any problems or wastes in the flow. Moreover, a value stream map helps to provide a common language and a plan for improvement..

[Audio] Waste applies to any part of a product or service that does not meet customer requirements and expectations. In Lean manufacturing, anything that does not give value to the customer is considered waste. This includes unnecessary steps, excess inventory, long turnaround times and resources used without tangible benefit to the end product. Lowering and eliminating waste leads to increased efficiency and cost savings..

[Audio] Lean Manufacturing is a system of production that emphasizes reducing waste or activities that do not add value to a product or service, whilst maximizing those that do. Value-added activities are ones that add form and function to a product or service and the customer is willing to pay for them, whereas non-value added activities do not provide either form or function to the product and so the customer will not pay for them. The aim of Lean Manufacturing is to remove, simplify, decrease or incorporate non-value added activities to organize the production process and enhance effectiveness..

[Audio] Lean manufacturing is an important concept in the modern manufacturing industry - a set of principles designed to reduce or eliminate waste in production processes and create the most efficient outcome. Looking out for waste includes defects, overproduction, waiting, not utilizing employees, transportation, inventory, motion, and excess processing. It has been estimated that in a typical production process, 95% of the lead time is accounted for by non-value added activities, thus making it important to look for these wastes and work to reduce them in our production process..

[Audio] Having a clear understanding of the process, flow of information and material, and data driven decisions are all necessary prerequisites to effectively practicing Lean Manufacturing. It is important to recognize that 94 percent of manufacturing issues arise from poor systems, while only 6 percent are caused by worker mistakes..

[Audio] Lean Manufacturing is a continuous improvement methodology developed by Taiichi Ohno at Toyota in the 1940's to streamline production and remove waste from the manufacturing process. The Lean approach identifies seven types of waste: overproduction, waiting, transport, processing, inventory, motion, and defective goods. Reducing or eliminating this waste can result in cost savings and increased competitive advantage..

[Audio] Lean manufacturing focuses on reducing waste in the production process, including seven areas of service waste such as delay, duplication, unnecessary movement, unclear communication, incorrect inventory, opportunity lost and errors. Identifying and counteracting these seven areas of waste is essential for companies to become more efficient and cost-effective. It is important to know how to identify and address these service wastes for successful lean manufacturing..

[Audio] 5Ss of Lean Manufacturing is a widely used methodology which seeks to promote organization and efficiency in the workplace. It focuses on keeping operations orderly, standardized and consistent, rather than on the occasional exception. Visual aids, for example posters depicting the 5S terms, can be employed to remind and motivate employees to stick to this organized system. These visuals are such a ubiquitous element of Japanese factories that their presence is now taken for granted..

[Audio] LEAN Manufacturing is an approach to business process improvement that originated in Japan. At its core are three concepts: Seiri, Seiton and Seison. Seiri involves classifying items into necessary and unnecessary and removing the unnecessary. Seiton is the process of organizing items to minimize search time and effort. Seison is all about cleaning the working environment as a way of spotting potential problems and preventing accidents. Grasping how these three concepts work together is crucial for successful implementation of LEAN Manufacturing in any business..

[Audio] The 5S principles are an integral part of the Lean Manufacturing system which emerged in Japan in the 1950s. This system emphasizes organization and cleanliness and is designed to ensure that every workplace is clean and organized, with all necessary items easily found. It has five components: Seiri, Seiton, Seiso, Seiketsu and Shitsuke. Seiri is organizing and sorting out the workplace, eliminating clutter and non-essential items. Seiton is putting everything in its proper place and labeling it so it can be quickly located. Seiso is cleaning and maintaining all necessary items, while Seiketsu requires employees to maintain personal hygiene. Finally, Shitsuke is the process of developing self-discipline to sustain the system and prevent it from decaying. When utilized correctly, the 5S system helps organizations maintain an orderly and efficient manufacturing environment..

[Audio] Lean manufacturing is an approach to production which maximizes the use of resources and eliminates wastage. It runs on Kaizen, Cellular/Flow, Pull/Kanban, Quality at Source, Standardized Work, 5S System, TPM, POUS, Quick Changeover, Batch Reduction Teams, Visual Plant Layout, and Value Stream Mapping. This combination of elements creates an effective system for a smoother, more efficient manufacturing process. Implementing these components allows for greater production efficiency and reduced resource use..

[Audio] Production and distribution systems that are known as "push" prioritize finished goods inventory that are based on a forecast of sales, rather than customer demand. An example of this is the process of a car factory, where parts and subassemblies are produced following a predetermined schedule, regardless of customer orders..

[Audio] Takt time refers to the maximum rate at which a production process should produce items to meet customer demand. It is the available operating time to satisfy customer demands, and establishes the pace or cadence of the process. Takt time is a fundamental element of lean manufacturing, used to balance the various loads and identify the bottlenecks in the process, allowing for improvements to be made in the most efficient way..

[Audio] Flow is the topic of this slide. One piece flow links all activities and processes in the most efficient way possible, increasing value-added content while reducing waste. Eliminating waiting time between processes further increases the speed at which value is added..

[Audio] "Term "pull" in lean manufacturing is a response to customer need rate. Supply chain view is taken into account where activities move from downstream to upstream. Hence, nothing is produced in upstream until signal of need is received from downstream customer..

[Audio] Lean manufacturing is a production philosophy that focuses on the optimization of processes with the continual improvement of the value delivered to customers, while reducing waste and increasing efficiency. Aiming to produce exactly what the customer wants, exactly when and economically, Lean production is an aspiration towards perfection. Our discussion will focus on the processes of continuous improvement..

[Audio] I have presented to you an introduction to Lean Manufacturing. Lean Manufacturing was developed by the Japanese and is a philosophy that seeks to eliminate waste in all aspects of a firm's production activities, making it equally applicable to both service and administration processes. The 5 principles that Lean Manufacturing works on are Value, Value Stream, Flow, Pull and Perfection. The Toyota Production System is the cornerstone of Lean Manufacturing and it considers 7 Wastes, commonly referred to as Muda and utilises the 5 S methodology. That's the end of my presentation. Thank you for your attention..