Download as pdf or txt
Download as pdf or txt
You are on page 1of 60

Lean System &

Innovation
=
"
FIN "

Flemming Unwanted
Things
$

A
=
'#m£e
costing "

renren.IM
O .

Coloration
R .

HE
treanapkm 'T
( Removing
Unwanted )
T
Focus on
Productive
only
Stuffs

Tyga
,

¥.
.eu *on÷⑥
Rtm
\
a÷g±I
Lean -

System
IT
1-

Waste Without
--→
sacrificing
Minimization
Productivity

:)
I
I
.

I
Value focus
Optimizing
on
Value
added Activity

Ivan
Added
workflow

÷÷÷÷÷÷
Activity
( Doing
a
particular
work

preceded
÷

St -

7- wastes
C
<

Fathead panda
"

)
tuan System
#
Waste txfmmization
I
Remote
Y9a¥!ffAddQ
7 wastes
=

Remove
( Tim
-
WOOD )
NVA

Them
ones
I
Transportation
Value
Jarcntoy Added

;g÷I⇒¥¥en÷⇒
activities
I
Motion
67 Clean)
Waiting

I -
-
- TPM
Cellular
Six
Mfg
Sigma .
TRANSPORTATION

EE

!
International

÷
Smarty

P
are
Ramwaterial FI

100 AM

I
10001M€
Storage mods working
.

Le
= sanest
Obsolete
-

toy
=

Theft
=

( 1000owmorkhsx Motion
,

2nd )
7958¥ "
factory

@rfttK
WE
590ohm

1
had

&
Wailing ( Nog
III. )
:
aation .
Fm
packages

An

Overhearing

Purple

FEE "÷÷
-
Over -

production
.

=
.

car co I

.¥÷÷eo
.

n
I
if
team
=

I
Characteristics

Principles =

time
=

Waiting
Zero
:

.
tint sine

Qwerty Inventory
perfect
.

.
Waste .

Pull Housing
Minimizing
Continuous
Continuous flow of
-

smpnacmnt pdn

flexibility
.

time
Reducing
.

C changing as
per
changing situations )
.
Least CID
A

g-

Procuring 4 Producing

!
1E¥demanM
.am#mer
.ae by
Reunion
friemshed
good
m¥→F¥*⇒-cEF= ,
.sk#-d-EEI)io,oo@

-÷÷⇒
I
i

i
:÷÷÷÷÷
Pmn€-¥m
,
omfg

A
or

aEMaM⑤paE¥
Cteoooxsrmpdnytom
Purchase
siefhffales-eamg-mtmtand-CY.IE
I

Woman
,
I
Electronic Data Quotation from
e±±( )
Interchange Guppies


[⑤igtFn¥n①
9¥00
Fasig
Meat mm a

F¥÷*
¥¥
, a

*aoC
I

1-

HEI WII
0
÷÷÷÷
working
JFK youth
BA

Finney w
±

Ay A -
Essential Prerequisites Aims
T
-

how goods
.

3) est Audit
variety ay
.

. Meet customer
Supplier reliability Demand
.

Communion Lowest Possible


Good
.

cost .

° Demand Stability -

Til
gmpactg =
.

Asm
Hat
costhandling I
.

Defect Free Mat


.
labour Idle
sime f
'

Parenti aintenanee .

octennial defects

HE
-

to
Response

against
demand
customer
list
.

: Eliminate Waste
Proper Supplier
.

Premium product
prices
.
Reduce overhead Costs
hrs C Gross)
400ohm

:
Labour :

x9 Efficiency
3800hm .
I
→ cadet )
.

1-

option1 options

Produce
for
Produce as
as

per
Demand
capacity
A
Cng
Gan

?¥ob
:

4001430001$
feb
40¥04
MOE 600¥ 60004
statement Cost Normal
I .

af
as
for Scenario .

J f M A M A .

:::::÷÷÷ig
6504690
① Demoed

Closing Stu

Ang Stk

Coetzee)
.
3150k

3
&
3760

670
h
:3
:p
:
4060

430

560
h
.
3350

880

655L
'
1030
3650

955
a
4830

515
n

offing . B .

Eth .

⇒ 36800
c-

Hormel
Rs .
257600
=
( scenario
I
cost

I .

statement of cost cm )

J f- M A M I

Demand 3150 3760 4060 33503650 4830

Pdn .

H③
3110370
0.7
,
,
.

( 738004 260 1030

Cssa
C zoo
-

4830 )
4060 )
-

÷ 954 .
1084.2
273dL
off
=

1358hm
to# 159.54
Totaled
-14¥
73.68 -11084.2€ .

( 110 .
. .
x.

As
216,6011 -
.

=
wE④lw :X
Net 26 oh 95

1030 :
gf
x
:
to

IIT ¥f .

namely

( 257,60
-

216,601) ⇐
41,000
=
Katzen :

1365

do
¥

'

01565
=

= 37
=

Kai -

Zen

IT
TT

Change for Better


°

Continuous
Jngnacment
Tate lxfmagement
Effective
°

in Cost below
Helps Reducing
.

initial Standards .
.
Katzen
=

I
Small Sustained
Pyoutinely
,

over a

Incremental + +
period
Applied long
Charges time
of
-

fault Significant
⇐ -

mats
Tyson

Involve Workers
.
from tluetiplefunctions .

→ Elimination Waste in Production


of ,

Assembling
f
,
Distribution

→ Elimination
of
Work steps

Quality , Reduce Cost



Improve
& screen profit .
Improving productivity &

System processes

- Collective Decision Making


is
promoted
.
^
On :

Molo L C
-

Maruti )
I
=

3-
changes required by Kaiten :

I
Standard Reda in
Active
cost control
periodicity
Al
I potion
.

cost Redwin to for


Monthly ) Weekly
standard
Enyhgee@mieAanud7ash.a
Viviana Budget
repost from
= Setting
Mantey Process
I
.

Weekly
ease Study ( Tmmhh)
-

Teddies r

Discuss to
the Concept
-

Solve the Issue .

-
Connect the Issue with

the with
concept

Examples

Detail
-

Explanation in

-
Conclusion .

=
Cathy -
Pacific Airline

=
food

okay x2=2oc⑨
Simard
Lean 3 -

5-5
#
( workplace Organization tlethod ) .

I
Is -

SEN .

Eliminate Obstacle 4
Unnecessary
.

items

Remove fast not in Use

Unwanted 'd
Segregate Klahn
°

from Workplace
2¥ : SEE -

IN ORDER C SEMON )
#

Arrange items
necessary

it most Accessible
-

in
keep

&
Efficient Manner

Smooth
Make Woskfloo a
Eeg
-

3¥ :

SHINee ( s

Clean basis
Workplace an
Daily
-

Safe &
Easy to work

Detection of any problem


.
4- S : STANDARDISE ( Sedaka)
=

Standardize Best
practices
-

Colour codes usable items


for
-

Responsibility of
maintaining
SI

5- S
= gust
N
Cshitsuke)

proper Training &


-

Discipline
Continue on basis
regular
-
Next .

kaicasestndytsigcst
Case Scenario # 9

C Toys Ltd .
-

5- s
)
=
Leaned CTPID
"

Total -

Productive
Flat ntenance
-

/
car ⇒ i so
Maintenance
Seeing
=

1 Hyuga
.

Year
:

Rs
.

1,50001
.

-
.

Year 2
°
:

asoo§p④
Rs
.

year ,
Rs 40,0001
,
.
.
-
: .


305¥
service
.
.

.
Noose :

lathe
-

Book
fy 150,0001
-

= I
TPM
=

(
keeping
all
Equipments in top
-

condition to Avoid Breakdown


working
&
Delay in
Mfg .
Process)
A
( strives to achieve Perfect )
reduction
I

Aim of MM
=

:÷÷m
:
smarmy
NO :

Accidents

operational Efficiency of
C Maximize

Equipment ) .

Plant floor Workers ?


CJ mrduement if
4

tt@pmiCPID.Pseph.Jntneduch.9mp1ementt.g

institutionalize .
(

8- Rumors of
TPM

:(
Autonomous Routine Maintenance
Maintenance Lubricating
= cleaning , ,

Inspection ) by worker .

on his Own .

2) Planned
Scheduled lllfaintenance
:

Maintenance done .

C Based an
fast issues )

anabks when
Maintenance
not scheduled
Equipment for
production .

3) Quality .
Error Detection
process
"

Maintenance
Eliminate Ohelity Defects
'

=
4) focused Gmp remnant
-
.

Groups
of Employees working together
to achieve Dmp nonevent in Equipment

operation

D Early Equipment Homage


ment :

J Design New
mpnning g
Equipment
.

6)
EdwI aiming
:

Train Machine operators on

any
new development .
7) Safety eHealth
=
.

Zero Accident by Regular


Ensuring
Maintenance resulting Safety &

Health Management of Employees

8) TPM in Admin / office


Environment -

Use TPM in
office
work as well .
f- Pillars TPM
of

÷
need

{ {
&
{
re

s
god

far .ir
if
s

a
for
§ § is
§

5-
or

s
je k

a
s

or
B

W
r

9
'
OEE
=

Overall Equipment Effectiveness

OEE of Planned time


of production

.


#
that is
productive
)

are
① ( Perfect

truly
K =

Fiction
D
Defect free poets

;:
.de#ductionyCpeed.) n
.in
. ,

3) Own

D No stoppages C Performance

Fail ability ) .
Cndcgma )
Ay
DEE
( Eaph
.
:

:
=

Tp 85% )
7901 . 7951 .

7951 .

Availability Performance Ouelity


loss loses
loss -

- -

inner Reduced
Equipment failure Idling
- -
-

Breakdown Yield
Stoppages
-

setup Adj -
Reduced
-

Quality defects
speed .
8 Rework .
Formulae of OEG
=

D PlannedPoodnction :

:@ :⇒
7
A Aide ship time
i30
-

↳ g hours ( arose
Time )

⑦ I hours
( planned
Downtime)
-

Shur


.o.÷€÷E
I
on
:*' .
"
loss of Sime

↳ ±
to .

=

Availability

pdh
east

ratio
=

Ph7÷he⇒e¥fIiE
Planned
Time .


armed
pdn -
planned
Ux
Downtime
)
C Total time lost
Sime per
Shi f.)

]
ofeoatg time .
It Performance

ftp.hss.I
for Apdn
'

ratio

Act .
his .

(
time

( Prodigy
-
un Planned
.

)
Downtime
.

AApdnxttd.r-imep.n.JP/anned7alI#
I

:
x

:*:
tot
-

Sime
operating .
It ratio
Quality=
:

¥⇒
Act pain
.
-
Admit
due to
Sap

( Goodhart
Total count .
EE Hindustan .
Ltd .

tffgifgbility ⇐ Planned
,,!dn
-

www.medm
-

Planned production
Time .

( Planned product time


)
Metz .mg
Gross 2in
=
NO hrs
① Planned DT
.

dime lost =
Unplanned Donating

= 2ohm

AR 210 -

28
-2,0=-86.671

=
→ Perform # alia .

Affine Lfo EI 't


-

D Ostyak
.

2520

*
-
-

DEE =
86 .

671 × 85.74 .
× 90.1

=
66 .
86 of
=
Pacifico
ast
Compte)
2 Shifts / Dfw
Day ⇒ 6 eek ⇐
84Day

2 shifts / Day
X 6 Days / week

¥f/wmc
Xbiweeks
48 shifts : ( 944
weeks.

)
I
?
SEA : plannede-Dwnh.me

/
Peak
.

Lunch Sh :
30M .

prudish
.

.
Other Misc .
:

is①
-

Preventive Main 18h .

15M .

¥ofhII
Hnpknman
:
(4 weeks .
)

Zloeakdown

360M¥
:
'

C 6hm .
×6om)
840 mins
Setup Charges
:
.

( 14h a 60ms

fair fail .
-

.
240
I
mins

C 4h xbom ) -

Unplanned Moat
-

. 1440 mins
=
Unplanned 4 weeks
?
i.e
14hL :
.

Maintenance 48 shifts .

1440
)
Upm
shift
:
30
=
.

= mins .

-4g

→ Gross time # he .

/ Shift
whiff = 9hm

X 60mi/h
↳ 540
-

mins
=

⇒ ptannedpnodn.me

=
AT Prom- Downtime

-
-


40M
-

60M
) = 480 mins
A aight .

Pageantry

(
Planned
pdr
si me


aging
4 so

cso-→
= 450

93
=

PM
.

=
I .
Performance -
ratio
=

) piece

3M
Std cycle time
.

. -

Pasts produced
/ shift 140g CA
't
.

Pdn?
'

Part accepted faff =


Std
PR Act pdnx Time
f.
.

=
.

a
.

=
140×32 = 41
.

Far
) uso

93.331
=

=
HI .

Quality R
=

Gaddafi
a
-
-
Tudo -

DEE 93.751×93.331×93.571
=

=
81.87 of
=
AE
shr

=
.

Sp :
450

Rem :
I 95

316
D 4Wh
:

£5
Contend :
ihr =
zig
Effy
↳ A 24
-

= .

: .
Couth
/ hr .
=
Rs .

24
-

=
opportunity
RE BD cost
Main .

649 -
64001 -

1576
:

( -810 "

Rs
20Gt
O O
.

20480

300¥
. .
.

= =
=

Rs
6ohm
102401 1920£
.

soothed
.
.

=
=
1620%13,780
(60×27/1)
If
:

120hm Rs
51201
"

25601
-
.
-
-
.

( 1209244) 10,920
.

3240

256 of 3844 -
1Wh
Rs . 11260

( box 4860
:

5120 Hoh
Ipso 12880
!
640×27%6480

You might also like