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Intro-To-Lean Intro-To-Lean Lean Manufacturing Definition Lean has been defined in many different ways. “A systematic approach to identifying and eliminating waste(non-value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection.” By The MEP Lean Network Intro-To-Lean History Timeline for Lean Manufacturing Intro-To-Lean Lean manufacturing is a philosophy In 1990 James Womack, Daniel T. Jones, and Daniel Roos wrote a book called “The Machine That Changed the World: The Story of Lean Production-- Toyotas Secret Weapon in the Global Car Wars That Is Now Revolutionizing World Industry” In this book, Womack introduced the Toyota Production System to American. What was new was a phrase– Lean Manufacturing. How to Increase Profit? Intro-To-Lean Intro-To-Lean Muda (Waste) Taiichi Ohno (1912-1990), the Toyota executive who was the most ferocious foe of waste human history has produced, identified the first seven types of muda in manufacturing system: Storage Transportation Waiting Motion Process Defects Over-productionMuda is everywhere. Intro-To-Lean Lean Overview Intro-To-Lean Lean Manufacturing Tools 5S Value Stream Mapping Standardized Work Load Leveling Kaizen Kanban Visual Workplace Quick Changeover Andon Poka-yoke One-piece flow Cellular Manufacturing Intro-To-Lean Production Planning System (Push System) Intro-To-Lean Push or Pull? A push system Intro-To-Lean Push or Pull? A pull system Intro-To-Lean Kanban Operation Intro-To-Lean Finished goods Raw materials inventory Semi-finished parts PK PK PK WK WK WK Station 1 Station 2 Station 3 Semi-finished parts Material handler Order receiving RM RM RM 14 3 2 1 3 4 4 5 6 7 7 7 7 8 8 9 12 13 13 11 10 11 11 11 Intro-To-Lean Current State Map of A Case Study Example Intro-To-Lean Future State Map At which stations, are parts withdrawn? At which stations, are parts scheduled? Intro-To-Lean Which to Choose — MRP (ERP), or