work shop on LEAN MANUFACTURING on 22 oct 2010

dont worry

The man who will use his skill and constructive imagination to see how much he can give for a dollar, instead of how little he can give for a dollar, is bound to succeed. ~Henry Ford

think it

before every minutes of action there should be a hour of thought................

Improvement usually means doing something that we have never done before. ~Shigeo Shingo

continous improvement

Continuous improvement is not about the things you do well - that's work. Continuous improvement is about removing the things that get in the way of your work. The headaches, the things that slow you down, that’s what continuous improvement is all about. ~Bruce Hamilton

vsm

Nature does constant value stream mapping - it's called evolution. ~Carrie Latet

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Blogger Buzz: Blogger integrates with Amazon Associates

Lead Time

Lead Time:

The time that elapses between receiving an order and shipping the product or service to the customer.

Batch-and-Queue

Batch-and-Queue

Producing more than one piece of an item and then moving those items forward to the next operation before they are all actually needed there. Thus items need to wait in a queue.

Also called "Batch-and-Push." Contrast with continuous flow.

OOPS!@#@$#@

OOPS - Hw it related to lean??... Hw to make OOPS to lean... THink and reply guys***

One Piece Flow

One Piece Flow

In its purest form continuous flow means that items are processed and moved directly to the next process one piece at a time. Each processing step completes its work just before the next process needs the item, and the transfer batch is one. Also known as "one-piece flow" and "make one, move one".

Waste - Types

1. Overproduction
2. Inventory
3. Defects
4. Overprocessing
5. Motion
6. People's Talents
7. Waiting
8. Transport
9. Re-Prioritzation

FIT MANUFACTURING CONCEPT

Fit Manufacturing is the Integrating Strategy that should Combine LEAN MANUFACTURING and AGILE MANUFACTURING to ensure the company SUSTAINABLE and COMPETITIVE in future.

Lean Manufacturing goal is to reduce waste as much as possible. In lean manufacturing, the company aims to cut all costs which are not directly related to the production of a product for the consumer.

Agile Manufacturing is an approach to manufacturing which is focused on meeting the needs of customers while maintaining high standards of quality and controlling the overall costs involved in the production of a particular product.

Lean Tools

ü 5 S

ü Error Proofing

ü Current Reality Trees

ü Conflict Resolution Diagram

ü Future Reality Diagram

ü Inventory Turnover Rate

ü JIT

ü Kaizen

ü Kanban

ü Lean Metric

ü LPI

ü Theory of Constraints

ü Total Productive Maintenance

ü Transition Tree

ü Value added to Non-value added Lead time ratio

ü Value Stream Mapping

ü Visual Management

ü Workflow Diagram

ü One-piece Flow

ü Overall Equipment Effectiveness

ü Prerequisite Tree

ü Quick Changeover

ü Standard Rate or Work

ü Takt Time

Continuous Flow

Each process (in the office or plant setting) makes or completes only the one piece that the next process needs, and the batch size is one - single-piece flow or one-piece flow - opposite of batch-and-queue.

5S

Five terms beginning with 'S' utilized to create a workplace suited for visual control and lean production. 'Seiri' means to separate needed tools, parts, and instructions from unneeded materials and to remove the latter. 'Seiton' means to neatly arrange and identify parts and tools for ease of use. 'Seiso' means to conduct a cleanup campaign. 'Seiketsu' means to conduct seiri, seiton, and seiso at frequent, indeed daily, intervals to maintain a workplace in perfect condition. 'Shitsuke' means to form the habit of always following the first four Ss.
• SORT
Eliminate everything not required for the current work, keeping only the bare essentials.
• STRAIGHTEN
Arrange items in a way that they are easily visible and accessible.
• SHINE
Clean everything and find ways to keep it clean. Make cleaning a part of your everyday work.
• STANDARDIZE
Create rules by which the first 3 S's are maintained.
• SUSTAIN
Keep 5S activities from unraveling

5 Whys

The 5 why's typically refers to

the practice of asking, 5 times, why the failure has occurred in order to get to the root cause/causes of the problem. There can be more than one cause to a problem as well. In an organizational context, generally root cause analysis is carried out by a team of persons related to the problem. No special technique is required

vibration one credit course

hi guys, we have our one credit course exam tom morning............all r invited