Thesis on lean manufacturing

thesis on lean manufacturing

It has been noticed that automobile industry is concerned about the cost delivery time, which are the key success factors for this industry. This is done by all within your organisation, lean values respect for people, involves everyone in the company to help meet customer value. In the 1980s it was very difficult to change a mass-production plant to lean production, because in mass production, workers were not expected to take responsibility for the quality of the product. We believe that the savings actually are higher for companies in Vietnam considering the higher levels of waste which they typically have compared.S. Recently, some companies in Vietnam have actively conducted training and implemented lean methods to eliminate process inefficiencies. This increases the risk of obsolescence, increases the risk of producing the wrong thing and increases the possibility of having to sell those items at a discount or discard them as scrap.

Thesis, topic on, lean, manufacturing!

Defects and wastage Reduce defects and unnecessary physical wastage, including excess use of raw material inputs, preventable defects, costs associated with reprocessing defective items, and unnecessary product thesis on lean manufacturing characteristics which are not required by customers. The results of TPS have included enormous advances in robotic manufacturing systems and factory design, just-in-time inventory management, the kanban system of visual inventory replacement cues, demand-pull management of manufacturing planning and others. (Taiichi Ohno, 1988) Waiting people waiting for machine or process; product waiting for people, machines or processes. Areas of Lean: Quality- Increasing quality. Beyond large scale production 7 categories of muda or waste:- Overproduction producing more unit than customers are demanding or producing them earlier than customer order them. Lean manufacturing is the production of goods using less of everything compared to traditional mass production: less waste, human effort, manufacturing space, investment in tools, inventory, and engineering time to develop a new product. Taiichi Ohno, the mastermind of the Toyota Production System, identified seven types of manufacturing waste, (2002 Poppendieck. History of Lean Manufacturing Toyota is often considered one of the most efficient manufacturing companies in the world and the company that sets the standard for best practices in Lean Manufacturing. Waste Not, Want Not, The Observer (September 2002). A second principle is that the supply chain should flow continuously, and so should the information that supports. Like their earlier work, this is both a landmark synthesis of ideas whose implications havent been fully understood and a breakthrough to new territory.

What are definitions for the Japanese terms. What features and services does the customer want? At present, the whole automobile sector is suffering from losses, which has led many businesses to shutdown. Lean construction is a combination of operational research and practical development in design and construction with an adaption of lean manufacturing principles and Dissertations and, thesis Research, projects. Jones, 1996) â thesis on lean manufacturing Manufacturing space per machine was reduced by 45; â Defects were reduced by 90 â Production cycle time was reduced from 16 weeks to 14 hours 5 days; and â Product delivery lead time was reduced from 4-20 weeks to 1-4 weeks. But eventually the line ran with very few problems, because the assembly workers felt responsible to find, expose, and resolve problems as they occurred. Equipment manufacturing company, Lantech, completed the implementation of lean in 1995, they reported the following improvements compared to their batch-based system in 1991: (James. These are typically industries for which productivity is highly influenced by the efficiency and attention to detail of the people who are working manually with tools or operating equipment. A more appropriate translation of such slogans as Zero Defects and Do It Right the First Time would be Test First.

Transportation Transportation includes any movement of materials that does not add any value to the product, such as moving materials between workstations. Get help with your essay today, from our professional essay writers! The main benefits of this are lower production costs, increased output and shorter production lead times. The truly lean plant has two key organizational features: It transfers the maximum number of tasks and responsibilities to those workers actually adding value to the car on the line, and it has in place a system for detecting defects. While on a tour of a large customer, Michael Dell saw technicians customizing new Dell computers with their companys standard hardware and software.

Lean manufacturing - Wikipedia

They remove the ability to be able to react to customer changes, to adapt when there are supplier and internal problems. Q: Are the production manager of automobile industry aware of lean manufacturing benefits? Producing defective products or products requiring repairs adds the cost of extra manpower, materials, facilities and conveyance measures. Workers were encouraged to stop the line if anything went wrong, (a management job in mass production).Before the line was re-started, the workers were expected to search for the root cause of the problem and resolve. Lean focuses on flow, the value stream and eliminating muda, the Japanese word for waste. Lean manufacturing is a management philosophy derived mostly from the Toyota Production System(TPS) because Toyota Motor Companys Eiji Toyoda and Taiichui Ohno are given credit for its approach and innovations, this system identified as "lean" only in the 1990s. Similarly in software development, the key to rapid delivery is to divide the problem into small batches (increments) pulled by a customer story and customer test. Just in time is a type of operations management approach which originated in Japan in the 1950s. In other words, dont code unless you understand what the code is supposed to do and have a way to determine whether the code works. With the regulated economy steadily contracting, consumers have a broader range of decisions to make, from how to invest retirement funds, to what telecommunications provider to use, to what airline to fly at what price. Also, issues associated with reworking typically consume a significant amount of management time and therefore add to factory overhead costs. Over-processing, it refers to the works performed on product that adds no value.

Transportation moving product from one place to another. (Thomas ewart, 2000) Main Kinds of Waste Originally 7- 9 main types of waste were identified as part of the Toyota Production System. Product should be pulled by the customer, not pushed by the company. Delays and discontinuities in the supply chain process are often caused by starting and ending processes or information streams that could smooth things out if they were operated continuously. Flow Value from Demand The idea of flow is fundamental to lean production. Safety and morale- Ensuring safety. For example, Toyota Ben Thanh, a service center of Toyota in Vietnam, has implemented lean methods to significantly reduce the process time for its automobile maintenance service from 240 minutes to 45-50 minutes per car, and as a result. Do It Right The First Time It is instructive to explore the origins of the slogan Do It Right the First Time. Email : Facebook : Tanvirul Haque Mukut, lean Manufacturing: Lean Manufacturing A way to eliminate waste and improve efficiency in a manufacturing environment. What kinds of companies benefit most from lean?

De limitation of the study:-, there are some limitations of this thesis. Volume, space, and financing were not available in Japan to support such massive machines, so Ohno set about devising simple methods to change the stamping dies in minutes instead of hours. At first the line was stopped often, which would have been a disaster at a mass production plant. Over processing Performing operation that are unnecessary. Chapter 2 literature review Lean manufacturing is a technique that allows companies to be more responsive to quickly changing markets and more sophisticated demanding customers.

9, lean, manufacturing, principles to Kill the Jargon and Get Quality Results

This is Just In Time manufacturing (JIT producing what the customer wants when they want it! Defects In addition to physical defects which directly add to the costs of goods sold, this may include errors in paperwork, provision of incorrect information about the product, late delivery, production to incorrect specifications, use of too much raw materials or generation of unnecessary scrap. Auto sector presently, contributes 16 to the manufacturing sector which also is projected to increase 25 in the next 7 years, compared.-02. Lean is most widely used in industries that are assembly-oriented or have a high amount of repetitive human processes. Improved quality of the product.

Without this information how can you design your ideal system? Until and unless any initiative to reduce the cost and delivery time of product will not be taken, any improvement in the industry would not take place. Buyers get low quality products which reduces their confidence in Pakistani products. In competitive markets, the issue of lead-time is of great importance, it is the main driving factor for business profitability but people are less aware of the lean manufacturing its importance that can bring drastic improvement in Automobile industry of Pakistan. But lean manufacturing also has evolved into a business philosophy based on a unique set of practices, and the resulting business culture demonstrates how to use these to create a lean approach to other aspects of business;.

TPS pays particular attention to the waste of overproduction. However, read some of these definitions, the reason I say to do so is because I am very disappointed with regard to how many of these are written. What took the customer an hour could be done in the factory in minutes, and furthermore, computers could be shipped directly to end-users rather than making a stop in the corporate IT department. Inventory Inventory waste means having unnecessarily high levels of raw materials, works-in-progress and finished products. A truly lean thesis on lean manufacturing distribution channel only works with a really lean supply chain coupled to very lean manufacturing. Lean manufacturing is a generic process management philosophy derived mostly from the (Toyota Production, 1991) Toyota Production System (TPS) Womack, James., Jones, Daniel., and Roos, Daniel (1991).

A Comprehensive Study on, lean, manufacturing, process - Textile Learner

Pull means that nothing is done unless and until a downstream process requires. By the 1980s Toyota had increasingly become known for the effectiveness with which it had implemented Just-In-Time (JIT) manufacturing systems. The idea is to be able to make the product so fast that it can be made to order. Flexibility Have the ability to produce a more flexible range of products with minimum changeover costs and changeover time. The slogan Do It Right the First Time encouraged workers to feel responsible for the products moving down the line, and encourage them to stop the line and troubleshoot problems when and where they occurred. The single most effective mechanism for implementing lean production is adopting Just-in-Time, pull-from-demand flow. If something does not directly add value, it is waste. Pakistan has the highest number of CNG-powered vehicles in the world with more than.55 million cars and passenger buses, constituting 24 of total vehicles in Pakistan with improved fuel efficiency and conforming to the. This seemingly simple principle is the key to eliminating waste caused by such things as making the wrong product (one that nobody wants making the product at an unsuitable quality level, making too much or too little.

In many industrial processes, such non-value added activity can comprise more than 90 percent of a factorys total activity (Simon Caulkin, 2002). While lean consumption would be a sensible idea in any era, we see several convergent trends that we think make it inevitable and indeed, a competitive necessity now. The change in focus is essential, but implementing it can be difficult in todays international supply chain environment. Cycle Times Reduce manufacturing lead times and production cycle times by reducing waiting times between processing stages, as well as process preparation times and product/model conversion times. In the manufacturing world, time is money. In manufacturing, the key to achieving rapid delivery is to manufacture in small batches pulled by a customer order. Over-production Over-production is unnecessarily producing more than demanded or producing it too early before it is needed. This is what is known as a sub-optimizing measurement, because it creates behavior which creates local optimization at the expense of overall optimization. Transportation between processing stages results in prolonging production cycle times, the inefficient use of labor and space and can also be a source of minor production stoppages. Due to the limited time only top few Manufacturers are included in the research work, which are. That is, no part of any supply chain process should be started without a complete understanding of the demand destination of the final product that will complete the cycle. The work focuses on Manufacturers and assemblers of Automobiles industry located in Pakistan and which has the sales volume more than 10 million.

What Are the Principles and Concepts

Cellular Manufacturing Kanban- A system that uses replenishment signals to simplify inventory management. So if you want to implement lean manufacturing you must not just focus internally to impress your board and make short term gains, but focus on the customer to make sustainable changes that will help your company flourish in today's. These churn out standardized products at high volume. For example, lets say that the performance measurement of a stamping room is machine productivity. Waste elimination: Waste is anything that happens to a product that does not add value from the customers perspective. Q: What is the knowledge level of production people about the lean manufacturing? Purpose:-, the main purpose of this thesis is to determine the importance of lean manufacturing and create its awareness amongst the automobile industry of Pakistan, which then can be applied by the whole manufacturing sector of Pakistan. Manufacturing and, lean, systems (camls) was founded in 2007 at the University. Once this is understood, everything else is waste. (James Womack Daniel Roos, 1992). The smooth, continuous flow of work through each process ensures that excess amounts of inventory are minimized unnecessary raw material, work-in process (WIP finished goods, and excess operating supplies are wastes. Inventory levels Minimize inventory levels at all stages of production, particularly works-in-progress between production stages.

Visit m to see how we can help you! Waiting results in a significant cost insofar as it increases labor costs and depreciation costs per unit of output. This not only results in inefficient use of labor and equipment but the act of re-processing often causes disruptions to the smooth flow of production and therefore generates bottlenecks and stoppages. Formerly, it took skilled machinists hours, if not days, to change dies from one part to another. Waiting also includes small delays between processing of units. Over processing is as wasteful as insufficient processing. LLC Optimize across Organizations Quite often, the biggest barrier to adopting lean practices is organizational. In the simplest form, lean manufacturing means producing goods with less; it applies fewer resources without affecting the quantity or quality of the goods produced. Advantages of Lean Manufacturing: Increased overall productivity. In many industrial processes, such non-value added activity can comprise more than 90 percent of a factorys total activity. Without missing a beat, Dell replied, Absolutely, wed love to do that.4 Within a couple of weeks, Dell was shipping computers with factory-installed, customer specific hardware and software.

(PDF) A literature review of lean manufacturing

Org/ Sharing Knowledge: Students, teachers and professionals thesis on lean manufacturing can publish your article here. If there is a way to do without it, it is waste. In addition to rapid, Just-in-Time information flow, Lean Software Development means rapid, Just-in-Time delivery of value. Q: Are the production manager of automobile industry aware of lean tools? At present, there are about 82 vehicles assemblers in the industry producing passengers cars, light commercial vehicles, trucks, buses, tractors and 2/3 wheelers. Workers are neither trained nor encouraged to worry about such things. As a part of this change it requires everyone to involve for looking beyond the boundaries of the company to relationships with customers and suppliers at all levels. Waiting Waiting is idle time for workers or machines due to bottlenecks or inefficient production flow on the factory floor.

Qualified writers in the subject of management are ready and waiting to help you with your studies. Better yet, if the order can be fulfilled by downloading it on the Web, there really isnt any order status necessary at all. They took all the elements of a manufacturing system people, machines, tooling, and products and arranged them in a continuous system for manufacturing the Model T automobile. Lean Manufacturing is becoming an increasingly important topic for manufacturing companies in developed countries as they try to find ways to compete more effectively against competition from developing countrie. Output Insofar as reduced cycle times, increased labor productivity and elimination of bottlenecks and machine downtime can be achieved, companies can generally significantly increased output from their existing facilities. Preface to the 2003 Edition.

Similarly, the single most effective mechanism for implementing Lean Development is delivering increments of real business value in short time-boxes. This would allow many parts of a car to be made on the same line with the same equipment. There are 500 auto-parts producers in the country that supply parts to original equipment manufacturers. Problem discussion: Pakistans automobile thesis on lean manufacturing industry is losing its competitiveness in the market due to the intense competition faced from world markets in terms of cost delivery time. However, there are some cases when an extra supply of semi-finished or finished products is intentionally maintained, even by lean manufacturers. Seiri, Seiton, Seiso, Seiketsu, Shitsuke. The number and type of tool depends on the product that is to be produced and production system of the product. The effect of pull is that production is not based on forecast; commitment is delayed until demand is present to indicate what the customer really wants.

Lean, manufacturing, a total quality management philosophy ToolsHero

For these kinds of companies, improved systems can eliminate significant levels of waste or inefficiency. Toyota Ben Thanh achieved significant reductions in the process lead time by successfully eliminating unnecessary waiting time, inefficiencies of physical motions and process flow. Vehicles manufacturers directly employ over 192,000 people with a entire investment of more than.5 billion. The selfish thesis on lean manufacturing drive to reduce costs wrongly assumes value on the part of the customer and the organisation tends to become not lean but anorexic! Lean manufacturing is the production of goods using less of everything compared to mass production. If you do nothing but add value, then you should add the value in as rapid a flow as possible.

Transportation, moving material between plants, between work centers, and handling more than once is waste. If you follow this process you will not be going through a process of waste elimination and reduction but a more important process of waste prevention! Q: To understand the issues of adoption of lean manufacturing in automobile industry in Pakistan? Sorensen, fashioned the first comprehensive Manufacturing Strategy. House of Lean, role of Lean for Producers: Role of Lean for Customers: Lean Manufacturing Tools: Lean manufacturing in a factory is maintained by several tools. Lean is the systematic approach to identifying and eliminating waste through continuous improvement by flowing the product or service at the pull of your customer in pursuit of perfection. Inventory Raw material, work in process (WIP finished goods in excess of direct customer requirement. Kanban- system References: www.

More specifically, some of the goals include:. This article will Define 5S and each Just-in-time (JIT) manufacturing, also known as just-in-time production or the Toyota Production System (TPS is a methodology aimed primarily at reducing flow times. Indus Motor Company -Toyota Motor. Master in Manufacturing Engineering. Ford was so incredibly successful he quickly became one of the worlds richest men and put the world on wheels. In mass-production days, filling orders immediately meant building up lots of inventory in anticipation of customer orders.