Implementing Lean Manufacturing why what how Vrunda Consultancy

Implementing Lean Manufacturing - why, what & how Vrunda Consultancy Service L # 8, New Lake View Co-op Soc, Ahmedabad-15 URL : www. vcs. co. in, Telefax : +91 79 26309223

Lean Manufacturing – Compulsive need to overcome problems • Delivery failures • Excessive rejection, rework, customer complaints • High cost of inventory & Damages due to handling • Capacity constraints due to high setup time • Abnormal manpower turnover & high attrition costs necessitates changes in systems and work practices and the way out is LEAN MANUFACTURING High Value & Customer Satisfaction. www. vcs. co. in

Lean Manufacturing – from Good to Great performances Lean manufacturing enhances competitive advantage by helping • Lower manufacturing cost with higher Productivity • Improve Quality • Shorten time to Deliver • Deliver on-time, every time • Be responsive to customer needs through improved workflow High Value & Customer Satisfaction. www. vcs. co. in

Lean Manufacturing – a paradigm to get more from less Lean manufacturing aims at improving systems and practices to deliver more and better value with lesser inputs and considers use of resources for any goal other than creation of value for customer as undesirable and to be wasteful and, therefore, a target for elimination High Value & Customer Satisfaction. www. vcs. co. in

Lean Manufacturing – targets all types of waste Focus of lean manufacturing is on eliminating waste due to Over-production …………. . . … making in excess of demand Defectives …………………. … products not meeting customer requirements Over-processing ……………. . doing more than is necessary Inventories …………. more WIP than the absolute minimum Waiting ……………. . . delay between processing steps Transportation ………………. . unnecessary transport of materials Movement …………. . unnecessary movement of people during the course of their work Untapped Talent ………. . …. … idle or under-utilized human resource High Value & Customer Satisfaction. www. vcs. co. in

Lean Manufacturing - structured & systematic process of change Lean manufacturing initiative proceeds systematically through five steps n. Specify value from customer’s perspective n. Map value stream n. Recognize & eliminate wastes n. Create work flow and pull system of production n. Target achieving perfection & sustain the changes High Value & Customer Satisfaction. www. vcs. co. in

Lean Manufacturing – multipronged actions with diverse tools Each step in lean manufacturing program uses tried & tested tools & techniques Steps Tools & Techniques Specify value to customer Map value stream • Voice of Customer • Value Stream Mapping • Project Charter • Process Flow analysis • Metrics Analysis Recognize & eliminate Wastes • Waste Analysis Create work flow and Pull system of production • Standard Work • Root cause analysis • Mistake Proofing • Create 5 -S Organization • Visual Management • Autonomous Maintenance Target achieving Perfection & sustain the changes • Standard Operating Procedures • Production levelling • Control Plan • Facility layout • SPC & SQC • One Piece Flow • Kanban • SMED High Value & Customer Satisfaction. www. vcs. co. in

Lean Manufacturing : 1 st priority is lead time & inventory reduction Survey of companies that implemented Lean Manufacturing shows that their first priority was to gain advantage in Lead Time and Inventory reduction LEAD TIME % of Companies No Change 4% Decreased up to 25% 38% Decreased 25%-50% 30% Decreased more than 50% 28% INVENTORY % of Companies No Change 18% Decreased up to 25% 30% Decreased 25%-50% 33% Decreased more than 50% 19% Source: Ingersoll Engineers’ Study in “Making Manufacturing Cells Work” Edited by Lee R. Nyman High Value & Customer Satisfaction. www. vcs. co. in

Lean Manufacturing : Steps in Consulting Assignment • Assessment - pre visit information • Assessment - on site evaluation • Proposal submission - cost & time estimates • Implementation High Value & Customer Satisfaction. www. vcs. co. in

Lean Manufacturing : Implementation • Lean startup – – – Lean training & team formation Identification of wastes with team Preparing future state map Prepare action plan to achieve future state Breakup into small projects with time line, mile stones, award/reward and celebration • Tools to be used – – 5 - S Organization, Own your Machine Initiative Multi Machine manning, SMED, POUS Re-Layout Other tools as identified during assessment High Value & Customer Satisfaction. www. vcs. co. in

Lean Manufacturing: VCS Team • Consultants are recognized for their unique experiences & continuing development of lean concepts with an enterprise perspective • Consultants have significant experience in manufacturing industries • All consultants are engineering graduates with post graduation in Management or Industrial Engineering High Value & Customer Satisfaction. www. vcs. co. in

Lean Manufacturing: VCS’s Consulting Support • VCS deploys a Senior Consultant to provide the training and guidance to teams for 8 – 10 days / month for a period of 6 months or as identified during Assessment. • In addition, one consultant may be based full time at client’s plant to regularly interact with teams and provide help in analysis, solution generation & evaluation and implementation. • The two members’ team generally works under the guidance of a Lead Consultant who visits the company once a month. High Value & Customer Satisfaction. www. vcs. co. in