The
concept of lean and lean manufacturing is developed by Toyota, Japanese auto maker
.In 1988,Ohno introduce the Toyota Production System(TPS).Then later it was
research and studied by the various researcher from manufacturing industries
.Then later it was named as “Lean Manufacturing System” by MIT professors to
interpret the Toyota Production System(TPS).
Lean Manufacturing System is
contrast to the mass production system developed by Hendry Ford.Lean
Manufacturing System is a popular tool in industries sector for past two
decades. Particularly in managerial sectors are attempted to implement Lean
Manufacturing System to improve the productivity and reduce the wastages. In
this regard to quality, cost, Just In Time (JIT), continuous improvement have
received more attention to implement Lean Manufacturing System.
In other word
Lean Manufactures are made a efforts to produce their goods with high efficient
in cost, quality and JIT delivery to the customers.
The basic idea of lean concept is to sequence the operation or production, in order to improving the productivity by reducing the unnecessary, un reasonable, Non-Valve added activity (NVA) and to promote the valve added (VA) activity
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One Point Info:
·
Valve
added activity (VA); Activity which added some valves to the
output/customer service or goods
(Eg: Inspection, Testing,
Production)
·
Non-Valve
added activity (NVA); Activity provide no value for internal or external
customers, and can be immediately eliminated.(Eg; Operator movement, rework
, defects )
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Basic Principle of Lean:
• To reduce transfer distance
of materials (from dock to process and from process to process).
• To reduce dock-to-dock for
the entire plant and for individual departments.
• To reduce inventory between
processes and within a process.
• Distance compression between
processes.
• Eliminate barriers for a
optimal production and material flow.
• Expose and eliminate non
valve added activities
• Subject all layout decisions
to the goals and objectives of the organization and the production system
• It promote Just In Time
(JIT) which helps to reduce the inventory level and to reduce the working
capital of asset and to work according to customer order.
One Point Info:
· Dock: an enclosed area in a company for the loading, unloading, of raw material and storage off finished good.
· Dock To Dock(DTD); Dock To Dock measure the product flow speed in a company or factory ,for effective product flow control .It includes from the stage of raw material to Work In Progress to finish product to packing stages .
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Benefits of Lean concepts:
• Increase
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Space utilization
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Production control
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Visual management
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Effective production management
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Overall Equipment Effectiveness
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Overall labor Effectiveness
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Sustainability
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Employee satisfaction
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Plant profits
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Error proofing system
• Decrease
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Dock-to-Dock time
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Investment in facility additions
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Capital costs for equipment and support services
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Work-in process and other inventory
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Material handling costs
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Product lead time
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Accidents
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