Automation Lean Manufacturing KALLOL DATTA Lean Manufacturing Defined

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Automation & Lean Manufacturing KALLOL DATTA

Automation & Lean Manufacturing KALLOL DATTA

Lean Manufacturing Defined Lean manufacturing system is a management technique that embraces all aspect

Lean Manufacturing Defined Lean manufacturing system is a management technique that embraces all aspect of production method for reduction of waste from the value stream to remain competitive. Lean is a systematic method for the elimination of waste(MUDA) in manufacturing process. Lean takes into account waste created through over burden (MURI) and unevenness(MURA)

Cont: In general seven type of classic waste are noticed in manufacturing environment :

Cont: In general seven type of classic waste are noticed in manufacturing environment : * over production * waiting * defects and errors * excess motion and movement * excess inventory * inefficient process * excess transportation

Cont: These classic types waste can be seen on a daily basis in many

Cont: These classic types waste can be seen on a daily basis in many production environment – mostly with high degree of manual operation. Further analysis has identified two other types of waste that Lean can address: Talent : Effect of poor or inadequate training or an operator interface that is poorly designed which may lead to operators errors. Energy: Many production system found not to be energy efficient.

Lean Manufacturer: To become competitive one must become Lean Manufacturer by attacking waste every

Lean Manufacturer: To become competitive one must become Lean Manufacturer by attacking waste every where by establishing best process and using right kind of Production System – that enable us to : - Reduce Inventory, - Eliminate down time, - Reduce space requirement, - Avoid errors / mistake ( Poka-Yoke) - Intelligently monitor and track production - Avoid over production - Shorten transport routes

Right Production System: The helpful approach to choosing the right production system is to

Right Production System: The helpful approach to choosing the right production system is to think in terms of production volume and product mix. There could be four type of production system like - Manual production system - Modular production system with some automation - Stand alone automated production cell - and fully automated production

Automation in Lean manufacturing system and Automation can coexists. Although many Lean purist content

Automation in Lean manufacturing system and Automation can coexists. Although many Lean purist content that Lean goal conflicts with using automation. With the right introduction of Automation, Lean system can improve manufacturing process and boost quality and productivity. However we must remember cost of Automation is high and Automation is not flexible. Where in human working is much flexible than machine.

Cont: Some condition where Automation can be used for better result: - where production

Cont: Some condition where Automation can be used for better result: - where production volume is high - the working condition is unhealthy for human in long term, like shot blasting and Painting. -the working condition is dangerous or difficult to approach by operator. - heavy loading such as moving of semi finish product repeatedly. - the process demands very fine and accurate finish. - the job is repetitive and simple. .

Conclusion: Finally there is no conflict between Automation and Lean Manufacturing , actually ,

Conclusion: Finally there is no conflict between Automation and Lean Manufacturing , actually , they are supporting each other to improve the competitiveness of the organisation. “ THANK YOU”