Lean PPT2 a rellicense hrefhttp creativecommons orglicensesby4 0img

Lean PPT-2 <a rel="license" href="http: //creativecommons. org/licenses/by/4. 0/"><img alt="Creative Commons License" style="border-width: 0" src="https: //i. creativecommons. org/l/by/4. 0/88 x 31. png" /></a> Lean PPT-2 by Dr. R. Gnanaguru is licensed under a <a rel="license" href="http: //creativecommons. org/licenses/by/4. 0/">Creative Commons Attribution 4. 0 International License</a>.

Lean Manufacturing Dr. R. G. Unit II Lean Tools and Methodologies Problem solving tools – Cause and Effect Diagram, Pareto analysis, FMEA, Work cell and equipment management tools – Process Mapping, Spaghetti diagram, U shaped Layout, Poke Yoke, Kanban, Andon, SMED, One Piece Flow, Genechi Genbutsu, Milk run, Visual work place, Quality at the source Methodologies – Pillars of Lean Manufacturing – Just in Time, Jidoka, 5 S, TPM, Six Sigma, DFMA, Kaizen.

Lean Manufacturing 2. 1. PROBLEM SOLVING TOOLS Dr. R. G.

Lean Manufacturing 2. 2. CAUSE AND EFFECT DIAGRAM Dr. R. G.

Lean Manufacturing Procedure to create Cause and Effect diagram: Dr. R. G.

Lean Manufacturing Dr. R. G.

Lean Manufacturing 2. 3. PARETO ANALYSIS Dr. R. G.

Lean Manufacturing 2. 4. FMEA (Failure modes and effects analysis ) Dr. R. G.

Lean Manufacturing 2. 5. WORK CELL Dr. R. G.

Lean Manufacturing Dr. R. G. 2. 6. EQUIPMENT TOOLS MANAGEMENT • It's reusable as is - return it to a storage location. • It needs reconditioning, so send it out for repair or re-sharpen it. • It is un-repairable - discard it.

Lean Manufacturing Basic Features for Tool Management • Tool/part number. • Description. • Price. • Quantity requirements. • Where used by shop floor, machines, jobs and users. • Minimum/maximum inventory levels. • Reorder point. • Vendor information. • Lead times. • Custom and standard reports. Dr. R. G. • Tool issue tracking by employee, date, job and profit center/machine. • Support transactions. • Ease of use. • Tool storage stations. • Process new and regrind tool activities. • Tool tracking cross-reference. • Tool availability. • Status reports. • Ordering reports. • Basic inventory information reports. • History information.

Lean Manufacturing 2. 7. PROCESS MAPPING Dr. R. G.

Lean Manufacturing Dr. R. G. Benefits of process mapping: Process mapping spotlights waste, streamlines work processes and builds understanding. Process mapping allows you to visually communicate the important details of a process rather than writing extensive directions. Increase understanding of a process Analyze how a process could be improved Show others how a process is done Improve communication between individuals engaged in the same process Provide process documentation Plan projects

Lean Manufacturing Process mapping symbols: Dr. R. G.

Lean Manufacturing 2. 8. SPAGHETTI DIAGRAM Dr. R. G.

Lean Manufacturing SPAGHETTI DIAGRAM Dr. R. G.

Lean Manufacturing 2. 10. POKE YOKE Dr. R. G.

Lean Manufacturing Dr. R. G. To overcome the inefficiencies of inspection through the use of automatic devices called Poka Yoke, these seek to do three things; Not accept a defect for the process Not Create a Defect Not Allow a Defect to be passed to the next process POKA YOKE CAN BE CATEGORIZED AS: Control – they take physical action to prevent a defect Warning – They sound an alarm or light up to tell us a mistake has been made.

Motion Stop Poka Yoke Lean Manufacturing Dr. R. G. Types of Poka Yoke: Contact Poka Yoke Fixed Value Poka Yoke Motion Stop Poka Yoke

Lean Manufacturing 2. 11. KANBAN Dr. R. G.

Lean Manufacturing 2. 12. ANDON Dr. R. G.

Lean Manufacturing 2. 13. SMED (Single-Minute Exchange of Die ) Dr. R. G.

Lean Manufacturing Dr. R. G.

Lean Manufacturing 2. 14. ONE PIECE FLOW Dr. R. G.

Lean Manufacturing 2. 15. GENCHI GEMBUTSU “go and see for yourself” Dr. R. G.

Lean Manufacturing 2. 16. MILK RUN Dr. R. G.

Lean Manufacturing 2. 17. VISUAL WORK PLACE Dr. R. G.

Lean Manufacturing Dr. R. G.

Lean Manufacturing 2. 19. PILLARS OF LEAN MANUFACTURING Dr. R. G.

Lean Manufacturing 2. 20. JUST IN TIME JIT aims to achieve the following objectives: Zero inventory Zero breakdowns 100% on time delivery Elimination of Non value added activities Zero defects. Dr. R. G.

Lean Manufacturing Dr. R. G.

Lean Manufacturing 2. 21. JIDOKA Jidoka is about quality at source, or built in quality Jidoka principles: Discover an abnormality STOP Fix the immediate problem Investigate and correct root cause Dr. R. G.

Lean Manufacturing 2. 22. 5 -S Dr. R. G.

Lean Manufacturing 2. 23. TPM (Total Productive Maintenance ) Dr. R. G.

Lean Manufacturing Big Losses 1 2 OEE Loss Classification Machine Breakdowns Downtime Loss Setup Loss and Minor Adjustments Downtime Loss 3 Dr. R. G. Examples Fan belt breakage, tool failures, motor breakdown Product change-over, staff shortage, material shortage Inspection, jams, adjustments, blocked Minor Stoppages Speed Loss 4 Slow Running Speed Loss Poor settings and alignment 5 Start-up Errors Quality Loss scrap and rework 6 Product Defects Quality Loss scrap and rework sensing devices,

Lean Manufacturing 2. 24. SIX SIGMA The DMAIC project methodology has five phases: The DMADV project methodology, known as DFSS ("Design For Six Sigma“): Dr. R. G.

Lean Manufacturing DFMA stands for Design for Manufacture and Assembly. Dr. R. G.

Lean Manufacturing PRINCIPLES IN DESIGN FOR MANUFACTURING AND ASSEMBLY: 1. Minimize number of components. 2. Use standard commercially available components. 3. Use common parts across product lines. 4. Design for ease of part fabrication. 5. Design parts with tolerances that are within process capability. 6. Design the product to be foolproof during assembly. 7. Minimize use of flexible components. 8. Design for ease of assembly. 9. Use modular design. 10. Shape parts and products for ease of packaging. 11. Eliminate or reduce adjustment required. Dr. R. G.

Lean Manufacturing 2. 26. KAIZEN Dr. R. G.

Lean Manufacturing Additional Topics: Shadow boards Clock chart Dr. R. G.

Lean Manufacturing Shadow boards Dr. R. G.

Lean Manufacturing Clock chart Dr. R. G.

Lean Manufacturing Dr. R. G. Assignment – 2 : Prepare a Shadow board using thermocool for keeping the following item: 1. Pen, 2. Pencil, 3. Eraser, 4. Sharpener, 5. Scale, 6. Marker pen, 7. Sketch pen, 8. Cello tape, etc. ,