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Operations Management: Course Instructor: Mansoor Qureshi
Operations Management: Course Instructor: Mansoor Qureshi
Management
Topic – Lean Operations & JIT
Course Instructor:
Mansoor Qureshi
What is “Lean Manufacturing?”
• Lean manufacturing is aimed at
elimination of waste
• Organize processes to add value to the
customer
• Deliver goods “just-in-time”
• Service organizations also using lean
• “The Machine That Changed
the World”
• Toyota auto manufacturing
• “Value chain”
Lean Production
• Lean Production can be defined as an
integrated set of activities designed to
achieve high-volume production using
minimal inventories (raw materials, work in
process, and finished goods)
Note how the flow lines are going back and forth
Heat Treat
Grinder
1 2
Saw Lathe Lathe Press
Heat Treat
Grinder
Saw Lathe A B Lathe Press
Basic Lean Principles
• Add nothing but value
– Eliminate “muda” – waste
• Do it right the first time
• People doing the work add value
– Team oriented
• Deliver on demand
– “Pull” instead of push
Lean = Eliminating Waste
Non-Value-Added:
Hold all waste in a
Value-Added “CLOSED MITT”
• Complexity
• Labor
• Overproduction
• Space
• Energy
• Defects
• Materials
• Idle Materials
•Transportation
•Time
Typically 95% of all lead time is non-value-added
Complexity
The waste of doing things the hard way!
• Excessive paperwork
• Excessive approvals
• Redundancy
• Poor communications
Causes of complexity:
• Multiple “patches” on the process w/o fixing the root
cause.
• The “cool” factor of technology or machinery.
• Failing to look for the simple solutions.
Labor Waste
• Human effort that adds no value to the product
or service from the customers’ viewpoint.
KAIZEN
• Examples:
– Color-coded dies, tools, pallets
– Lines on the floor to delineate storage
areas, walkways, work areas etc.
– Location signs on shop floor and in the
office
Before 5S
Ultimate A
Goal balanced
rapid flow
Supporting
Goals Eliminate disruptions
Make the system flexible Eliminate waste