Introduction to Lean

Manufacturing
Lean Manufacturing Definition
Lean has been defined in many different ways.

“A systematic method for the elimination of waste

(MUDA) within a manufacturing system.”

By TPS

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History Timeline for Lean Manufacturing

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Lean manufacturing is a
philosophy
In 1990 James Womack, Daniel T. Jones, and
Daniel Roos wrote a book called “The Machine
That Changed the World: The Story of Lean
Production-- Toyota's Secret Weapon in the Global Car
Wars That Is Now Revolutionizing World Industry”

In this book, Womack introduced the Toyota

Production System to American.

What was new was a phrase–

"Lean Manufacturing."
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How to Increase Profit?

Profit
Cost

Profit Profit
Cost Cost

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Muda (Waste)
Taiichi Ohno (1912-1990), the Toyota executive who was the most
ferocious foe of waste human history has produced, identified the
first seven types of muda in manufacturing system:

• Storage
• Transportation
• Waiting
• Motion
• Process
• Defects
• Over-production
Muda is everywhere.
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Intro-To-Lean
Lean Overview

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Lean Manufacturing Tools
 5S
 Value Stream Mapping
 Standardized Work
 Load Leveling
 Kaizen
 Kanban
 Visual Workplace
 Quick Changeover
 Andon
 Poka-yoke
 One-piece flow

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The Objections to Lean
How should you deal with these objections to lean?
•“It is very hard to deal with raw material suppliers
if we fully depend on customer order.”
•“It takes too much discipline.”
•“It takes too long to implement.”
•“My process is too complex; I have to deal with
too many uncontrollable variables, like late supplier
shipments, sick people, etc.”
•“My process requires a large batch size.”
•“It doesn’t make sense in my industry.”
•“It’s unclear to me how lean will work with my
system.”
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Lean and Green
The environmental impacts due to
production and waste generation
have made its way into every day
society.
Consumers are becoming more
environmentally conscious.
With the Earth’s limited resources,
companies are more conscious of
their carbon footprint, and there has
been a movement to create more
environmentally friendly decisions.
Green engineering is the systems-level approach to product and
process design where environmental attributes are treated as primary
objectives or opportunities rather than simple constraints.
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lean manufacturing is a link
to green engineering
Lean manufacturing is the business model and collection of tactical
methods that emphasize eliminating non-value- added activities
(waste) while delivering quality products at lowest cost with greater
efficiency. In conjunction, six goals of green engineering are:
1. Select low environmental impact materials.
2. Avoid toxic or hazardous materials.
3. Choose cleaner production processes.
4. Maximize energy and water efficiencies.
5. Design for waste minimization.
6. Design for recyclability and reuse of material.

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lean manufacturing is a link
to green engineering
Population grows
Wastes increase
Fossil fuels are diminishing and there is nothing replenishing them.
Consumers are becoming more aware of the environment and
prefer environmentally friendly companies.
Being lean and green is so important now to reduce the
consumption of natural resources and the CO2 concentration
in the Earth’s atmosphere.

The only real difference between lean and green manufacturing is

that green actually designs the product or process with the
environment as a constraint while lean creates a process with the
view of the environment as a valuable resource and not a
constraint.
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 References
• Society of Manufacturing Engineers, Lean Manufacturing 2007,
Supplement to Manufacturing Engineering, 2007.
• Society of Manufacturing Engineers, Lean Manufacturing 2008,
Supplement to Manufacturing Engineering, 2008.
• Garrett Brown and Dara O’Rourke, “Lean Manufacturing Comes to
China: A Case Study of its Impact on Workplace Health and Safety,”
International Journal of Occupational and Environmental Health (IJOEH),
13(3), JUL/SEP 2007.
• Challenges in Applying Lean Manufacturing in China, McKinsey
Quarterly, 2006 Special Edition available at Jackson Library. Friday,
October 12, 2007 | Posted by Simone Yu in International

Intro-To-Lean