Lean manufacturing
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This document discusses lean manufacturing practices such as cellular layout, point-of-use storage, linked cell manufacturing, and the principles of lean systems including value, value stream, flow, pull, and continuous improvement. It also discusses how simulation software like WorkPro, ProModel, and Arena can be used for layout optimization, problem solving, and factory simulation to support lean practices. Ergonomics and its importance in lean is discussed. The goals of lean manufacturing are listed as less labor/floor space, fewer design/defect hours, less stock, faster delivery, improved ergonomics, and maximum flexibility.
Lean manufacturing
- 1. VIRTUAL LEAN MANUFACTURING Dr. V. RAMESH PROFESSOR SJCE, MYSORE
- 3. Functional layout Cellular layout Askin G.G & Standridge C.R. (1993) Modelling and Analysis of Manufacturing Systems, John Wiley ISBN 0-471-57369-8
- 4. 息 Siemens Power Generation Systems Functional layout
- 5. Manufacturing cells 息 Siemens Power Generation Systems
- 6. VIRTUAL LEAN MANUFACTURING PRACTICES FOR LEAN MANUFACTURING, LINE BALANCING, KAIZEN, FLOW PATH ANALYSIS, SMED, ERGONOMICS, SCHEDULING ANALYSIS WORKPRO FOR LAYOUT OPTIMIZATION PROMODEL FOR PROBLEM SOLVING INNOVATIVE WORK BENCH SIMULATION MODELLING ARENA
- 7. WORKPRO
- 8. WORKPRO ERGO STUDIES
- 9. PROMODEL
- 13. Lean Manufacturing? Large batches Excessive inventory Long lead times Excessive work in progress Disorganized shop floor with no space High costs Low percent of on-time deliveries Difficulty in meeting customer needs Not competitivehaving selling price too high
- 14. POINT OF USE STORAGE
- 17. Linked Cell Manufacturing System
- 18. Lean Production As Linked Cell
- 20. Top 10 Steps Of Lean Manufacturing
- 21. The Principles of a Lean Manufacturing System ValueCustomers willingness to pay for your product. Value StreamAdd-ons to a product or process. FlowThe movement of your product through a single piece flow or work cells rather than production lines. PullHaving the right amount of materials to manufacture the product, and at the same time, having a small or no inventory. Continuous ImprovementGetting rid of waste on a constant basis.
- 22. Light Duty Lean Manufacturing
- 28. Parts Organizers
- 29. Cross Tub Racks
- 30. Howardell Seven Skills Customer consciousness, Enterprise thinking. Adaptation, Taking initiative, Innovation, Collaboration
- 31. Hence, Lean Manufacturing Aims at, Less labor and floor space. Fewer design hours for product development. Less stock on hand. Fewer defects. Quality. Faster delivery. Improved ergonomics. Maximum flexibility in product types and styles produced.
- 32. Lean and Ergonomics Safety and ergonomics should be one of the core values of the lean process Identify work process to improve Stakeholder involvement Ergonomics training Ergonomic design Quantifying the impact of ergonomic changes Creating shared belief for the benefit of ergonomics
- 33. Waste Waste of motion that does not add value Can lead to muscle fatigue Waste of manual effort Can lead to muscle fatigue Waste of movements to transport material Can lead to muscle fatigue and strains Waste of time to rework, repair, or scrap May be related to fatigue, strains or sprains Focus on self and not on job
- 34. Multifunction double gantry mill 息 Siemens Power Generation Systems A single machine acting as a cell
- 35. Group Technology / Cellular Manufacturing Improved material flow Reduced queuing time Reduced inventory Improved use of space Improved team work Reduced waste Increased flexibility
- 36. Waller, D.L., 2003,Operations Management: a Supply Chain Perspective 2nd Edition, Thompson, London