LEAN MANUFACTURING Mitramatra

LEAN Principles, Tools &
MANUFACTURING Methods
I’M DANANG
I feel happy to be able to share
something with you, again
.
• Today, I’m senior business development in SGS

Indonesia.
• Since year 2004 – I have been IATF Automotive
auditor
• Previously I worked in Astra Daihatsu Motor (1995 –
2003)
• I have Six Sigma Master Black Belt in year 2001
• My frist job experience in Dirgantara Indonesia – Inc.
(IPTN) for N250 project for following period : 2
Copyright 2020 © DWI
1992 – 1995.
MY REFERENCES
There is a lot of reference material in
this world, and besides the experience
that I've done - I use the following
references :
• Toyota Production System: Practical Approach to Production
Management – by Yasuhiro Monden
• Japanese Manufacturing Techniques Nine Hidden Lessons In
Simplicity - Richard J. Schonberger
• http://insights.btoes.com/resources/lean-manufacturing-principles-
lean-tools-introduction-
• Lean Manufacturing: Principles, Tools and Methods by Bosch Group
• Recon®gurable manufacturing systems: Key to future manufacturing
- M. G. MEHRA B I , A . G . ULSOY and Y. KOREN Department of
Mechanical Engineering and Applied Mechanics, The University of
Michigan, Ann
3
WHAT IS LEAN The theory of lean manufacturing
has been built on the Toyota
Production System which was
MANUFACTURING initially learnt from the Ford’s

Production System
4
5
THE PRODUCTION PHILOSOPHIES HAVE

TO EVOLVE WITH NEW INNOVATIONS DUE
TO TECHNOLOGICAL ADVANCEMENT AND
UNLIMITED DEMANDS OF CUSTOMERS
• The theory of lean manufacturing has been built on the Toyota Production System
which was initially learnt from the Ford’s Production System.
• Therefore, the production philosophy and basic management principles adopted by the
Toyota Production System and the Ford’s Production System can be recognized as the
fundamental theories contributed to the development of lean manufacturing philosophy
THE MEANING OF
LEAN MANUFACTURING
Lean manufacturing is a systematic

method for the elimination of waste
("Muda") within a manufacturing system.
Lean also takes into account waste created
through overburden ("Muri") and waste
created through unevenness in work loads
("Mura").
6
THE MEANING OF
LEAN
MANUFACTURING
This concept focuses on key

processes of manufacturing
systems and improves the
organizational performance in
financial and non-financial terms.
Lean manufacturing is about
doing more with less; it involves a
never-ending effort to reduce
waste and non-value-added
International Journal of
Economics, activities.
7
CONTINUES Next product can be
introduced to the process
FLOW
as soon as the one before
has completed step one.
8
9
ONE-PIECE /
CONTINUOUS FLOW
The antithesis to 'batch' production,

continuous flow manufacturing is the
process of keeping a product moving from
the beginning of production to the
completion of the product.
It is used in manufacturing to maximise
efficiency against 'batching

FLEXIBILITY WITH The line could be a
simple line – for
SIMPLICITY flexibility
10
PROCESS DESIGN BASICS:
• CONTINUOUS FLOW
• SAVE FACTORY FLOOR SPACE
• NO EXCESS PRODUCTION
• NO EXTRA SHELF/DRAWER SPACE
• Since continuous-flow, one-at-a-time

manufacturing is another goal of lean
manufacturing, it is important that each
workstation or machine be designed to
fit within a minimal envelope.
• No WIP – process will done in one

continues Flow
11
TAKT TIME
Takt time is the rate at

which the finished product
needs to be completed, in
order to meet the
customer demand.
Outside of Lean, the term
references the german
word for a Baton used to
keep a tempo, or
a 'heartbeat'
12
HEIJUNKA
Heijunka is a Japanese technique for achieving a perfect supply
and demand balance. In other words, achieving an even output
flow by carefully coordinating very small production batches across
Simplicity is possible with Hiejunka the whole manufacturing line. Heijunka means ‘leveling.’ When
done correctly, it helps organizations meet demand elegantly, i.e.,
without haste. They meet demand while also reducing waste in the
production process
Ohno (1988) : “The slower but consistent

tortoise causes less waste and is much
more desirable than the speedy hare that
races ahead and then stops occasionally to
doze”
13
An efficiently organized
WORKPLACE workplace is the most

fundamental step to
guaranteeing the organization
ORGANIZATION
productivity and preparing it
for major expansions in the
future.
14
WORKPLACE
ORGANIZATION
Workplace
Organization
15
Basics:
• Organize tools with appropriate
tool holders
• Provide back-up tools at automatic
stations
• Insist on flexible tool mounting
structures
• Put the right information where it’s
needed
WORKPLACE
ORGANIZATION
Benefits:
16 • Minimize downtime
• Reduce wasted motion,
• Uninterrupted workpiece
flow
• Improve quality
• Flexibility

COMPONENT
An efficiently organized
workplace is the most
fundamental step to
VISUAL CONTROL
guaranteeing the organization
productivity and preparing it
for major expansions in the
future.
17
COMPONENT VISUAL MANAGEMENT
• One Piece Flow Supply parts as needed

• Parts loaded from outside the cell
• Use gravity feed as the preferred method
• FIFO parts presentation
• Flexibility support
• Error assembly detection capability
The benefits :
Easy reconfiguration, reduce
wasted
motion, uninterrupted
production, quick
changeover
18
must be rapidly designed, able
EASY TO CHANGE
to convert quickly to the
production of new models,
able to adjust capacity
quickly, and able to integrate
RECONFIGURABILITY
technology and to produce an
increased variety of products
in unpredictable quantities.
19
20
RECONFIGURABLE
MANUFACTURING SYSTEMS:
KEY TO FUTURE MANUFACTURING
• Changing manufacturing environment characterized

by aggressive competition on a global scale and
rapid changes in process technology requires to
create production systems that are themselves easily
upgradable and into which new technologies and
new functions can be readily integrated
• New approach must be rapidly designed, able to

convert quickly to the production of new models,
able to adjust capacity quickly, and able to integrate
technology and to produce an increased variety of
products in unpredictable quantities.

ZERO DEFECT
to convert quickly to the
QUALITY
21
22
ZDQ
ZERO DEFECT QUALITY
• Theory ensures that there is no waste

existing in a project. Waste refers to all
unproductive processes, tools, employees
and so on. Anything that is unproductive and
does not add value to a project should be
eliminated, called the process of elimination
of waste.

JIDOKA
AUTOMATION WITH HUMAN
TOUCH
"intelligent automation" or "Automation with a

human touch". This type of automation implements
some supervisory functions rather than production
functions. At Toyota, this usually means that if an
abnormal situation arises; the machine stops and the
worker will stop the production line. It is a quality
control process that applies the following four
principles:[2]
Detect the abnormality. Stop. Fix or correct the
immediate condition. Investigate the root cause and
install a countermeasure.
23
Long down times cannot be
MAINTAINABILITY
tolerated in a pull-through
system. When customer
demand exists, the product
must be produced..
24
MAINTAINABILITY
Maintainability Basics:
• Ease of service
• Manual back-up
• Put the operator manual on
the machine
• Standardize as many
25 components as possible
• Use common tools and
fixtures
• No finish work required on
system components.
• Minimum spare parts
necessary
Benefits:
Minimum down time, easy-to-
source
replacement
Copyright 2020 © DWI parts, quick
SIMPLE to convert quickly to the

CONSTRUCTION
26
SIMPLE
PRODUCTION LINE
• All controls or fixtures positioned with
ergonomics in mind
• All serviceable components at rear of
machine/workstation to eliminate
Interference of maintenance personnel
with production
• Clearance for all tools for ease of use
• All guards easy to remove with
• simple hand tools
Benefits:
• Minimum down time, easy serviceability,
• optimum ergonomic design.
27
WORKING
Productivity will achieved
with effective working
environment - Any properly
ENVIRONMENT
designed lean work cell must,
by definition, be good
working environment
designed.
28
WORKING ENVIRONMENT
FOR LEAN MANUFACTURING
Create Value
Value is one of the fundamental lean

concepts that underpins everything else.
Before attempting to streamline processes or
reduce waste, it’s vital to understand the
customer value that your organization is
29 striving to deliver.
It’s also important to ensure that this defined
value is aligned with client needs.
This is where the magic happens but
unfortunately for many companies, this
doesn’t always occur as readily as they’d
like.

HYBRID SYSTEMS
FOR
LEAN
MANUFACTURING
In keeping with the flexibility requirement

for lean manufacturing, there may be
times when a hybrid system rather than a
pure lean system is best for the
30 manufacturing Process
Hybrid manufacturing systems combine

the economies of the lean system with
the safety and efficiency of an automated
Final Considerations: Hybrid Systems
system.

ACTION FOR CALL
Kalau anda merasa belum

terlalu jelas dan butuh
bantuan – layangkan
kepada kami
THANK
YOU
Danang Widoyoko
+62 811196211
danangwid1987@gmail.com
bersamamitramatra@gmail.com

LEAN MANUFACTURING Mitramatra

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LEAN Principles, Tools &

• Today, I’m senior business development in SGS

MANUFACTURING initially learnt from the Ford’s

THE PRODUCTION PHILOSOPHIES HAVE

Lean manufacturing is a systematic

This concept focuses on key

The antithesis to 'batch' production,

Copyright 2020 © DWI

• Since continuous-flow, one-at-a-time

• No WIP – process will done in one

Takt time is the rate at

Ohno (1988) : “The slower but consistent

WORKPLACE workplace is the most

Copyright 2020 © DWI

• One Piece Flow Supply parts as needed

• Changing manufacturing environment characterized

• New approach must be rapidly designed, able to

Copyright 2020 © DWI

• Theory ensures that there is no waste

Copyright 2020 © DWI

"intelligent automation" or "Automation with a

SIMPLE to convert quickly to the

Value is one of the fundamental lean

Copyright 2020 © DWI

In keeping with the flexibility requirement

Hybrid manufacturing systems combine

Copyright 2020 © DWI

Kalau anda merasa belum

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