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Lean manufacturing.

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Manufacturing Engineering Assignment related to industrial visit Lean manufacturing is a term that is primarily associated with the automotive industry. It is the philosophy of achieving competitive manufacturing performance through the elimination of waste. Lean manufacturing has a number of techniques that are used to identify and eliminate waste. These techniques are the foundation of the lean manufacturing philosophy and are also used in many other industries. Toyota Seven Wastes The seven wastes originated in Japan, where waste is known as "muda". "The Seven Wastes" is a tool to further categorize "muda" and was originally developed by Toyota's Chief Engineer Taiichi Ohno as the core of the Toyota Production System, also known as Lean Manufacturing. To eliminate waste, it is important to understand exactly what waste is and where it exists. While products significantly differ between factories, the typical wastes found in manufacturing environments are quite similar. For each waste, there is strategy to reduce or eliminate its effects on a company, thereby improving overall performance and quality. The seven wastes consist of:- 1- Overproduction Overproduction is to manufacture an item before it is actually required. Overproduction is highly costly to a manufacturing plant because it prohibits the smooth flow of materials and actually degrades quality and productivity. The Toyota Production System is referred to as "Just in Time" (JIT) because every item is made just as it is needed. ...read more.


These cards are used to control work-in-progress (WIP), production and inventory flow. A Kan Ban system allows a company to use Just-in-Time (JIT) Production and Ordering Systems which allow them to minimize their inventories while still satisfying customer demands. A Kan Ban System consists of a set of these cards, with one being allocated for each part being manufactured, that travel between preceding and subsequent processes. The Kan Ban System was developed (over 20years ago), by Mr. Taiichi Ohno, to achieve objectives that include: - reducing costs by eliminating waste/scrap - try to create work sites that can respond to change quickly - facilitate the methods of achieving and assuring quality control - design work sites according to human dignity, mutual trust and trust and support, and allowing workers to reach their maximum potential. The two most common types of kanbans used today are:- 1) Withdrawal (Conveyance) Kanban 2) Production Kanban 1) Withdrawal (conveyance) Kanban:- The main function of a withdrawal kanban is to pass authorization for the movement of parts from one stage to an other. Once it gets the parts from the preceding process and moves them to the next process, remaining with the parts until the last part has been consumed by the next process. The withdrawal kanban then travels back to the preceding process to get parts thus creating a cycle. A withdrawal kanban usually carries the following information:- - Part number - Part name - Lot size - Routing process - Name of the next process - Location of the preceding process - Container type - Container capacity - Number of containers released. ...read more.


His plan is called Zero Quality Control (ZQC). Shingo identified three different types of inspection: judgment inspection, informative inspection, and source inspection. Basicly, Poka-Yoke's idea is to stop a process whenever a defect occurs and to prevent the recurring source of the defect. Visual Performance measures Performance measurement provides a tool for assessing the progress of an organization in achieving its defined goals and objectives. In doing so it provides managers and stakeholders with an understanding of how value is created and at what cost. Good performance measurement frameworks contain a relatively small number of performance measures ("the critical few") that are clearly linked to the organization's objectives, focused on the key performance issues, and are actionable, timely, valid and reliable, and readily understandable. Excellent Performance Indicators Excellent Performance Indicators (EPI) program was set up to encourage problem-solving skills and employee empowerment. The EPI program has evolved into an employee empowerment and recognition program based on metrics that measure team performance. The program rewards team accomplishments, provides the necessary tools to monitor data-driven performance, and encourages process improvements directed at reducing costs. The EPI programs goals include optimizing employee and team performance; continuous improvement in product quality; and increased sensitivity to internal and external customer/supplier relationships through employee involvement. Another aspect of the EPI program is training; some of which enhance employees educational needs while others target skills such as problem solving, effect and manage change, team building, and communications. Mazin Hassan Manufacturing Engineering and Management - 1 - ...read more.

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