LEAN

METHODOLOGIES

Lean Manufacturing

Lean manufacturing is one of

the initiatives that many major
businesses in the United States
have been trying to adopt in
order to remain competitive in
an increasingly global market.
The focus of the approach is
on cost reduction by
eliminating non-value added
activities.
Lean
Manufacturing
Originating from
the Toyota
Production Just In Time
System, many of
the tools and Cellular Manufacturing
techniques of lean
manufacturing SMED Single Minute exchange of dies

Five S

Kanban

Poka Yoke

Total Productive Maintenance

Production Smoothing
LEAN MANUFACTURING

Objective Overview

• Eliminate Waste • After World War II Japanese

Haga
• Maintain better inventory
control
texto
• Improve product quality
• Obtain better overall financial
and operational control
clic para manufacturers were faced with
agregar
vast shortages of material,
financial, and human resources.
These conditions resulted in the
birth of the “lean”
manufacturing concept
(Womack et al., 1990). Kiichiro
Toyoda, the president of Toyota
Motor Company at the time,
recognized that American
automakers of that era were
out-producing their Japanese
counterparts by a factor of
about ten
LEAN
MANUFACTURING

Cellular manufacturing

• Organizes the entire process for a particular

product or similar products into a group (or “cell”),
including all the necessary machines, equipment
and operators. Resources within cells are arranged
to easily facilitate all operations.

Just-in-time (JIT)

• A system where a customer initiates demand, and

the demand is then transmitted backward from the
final assembly all the way to raw material, thus
“pulling” all requirements just when they are
required.
LEAN
MANUFACTURING

Kanbans

• Kanban is a system to control the logistical chain

from a production point of view, and is not an
inventory control system. ERP Messages for
Purchas Orders.

Total preventive maintenance (TPM)

• Workers carry out regular equipment maintenance

to detect any anomalies. The focus is changed from
fixing breakdowns to preventing them. Since
operators are the closest to the machines, they are
included in maintenance and monitoring activities
in order to prevent and provide warning of
malfunctions.
LEAN
MANUFACTURING

Setup time reduction

• Continuously try to reduce the setup time on a

machine

Total quality management (TQM)

• A system of continuous improvement employing

participative management that is centered on the
needs of customers. Key components are employee
involvement and training, problem-solving teams,
statistical methods, long-term goals, and
recognition that inefficiencies are produced by the
system, not people.
LEAN
MANUFACTURING

SMED Single-Minute Exchange of Die

• It provides a rapid and efficient way of converting a

manufacturing process from running the current
product to running the next product. This rapid
changeover is key to reducing production lot sizes
and thereby improving flow. The phrase "single
minute" does not mean that all changeovers and
startups should take only one minute, but that they
should take less than 10 minutes (in other words,
"single-digit minute")

Five S
• There are five primary 5S phases: sorting, set in
order, systematic cleaning, standardising, and
sustaining.
LEAN MANUFACTURING
Five S
Sorting
Eliminate all unnecessary tools, parts. Go through all tools, materials, and so
forth in the plant and work area. Keep only essential items and eliminate what is
not required, prioritizing things per requirements and keeping them in easily-
accessible places. Everything else is stored or discarded

Straightening or Setting in Order to Flow or Streamlining

Arrange the work, workers, equipment, parts, and instructions in such a way that
the work flows free of waste through the value added tasks with a division of
labour necessary to meet demand.

Systematic Cleaning (Shine)

Clean the workspace and all equipment, and keep it clean, tidy and organized. At
the end of each shift, clean the work area and be sure everything is restored to
its place. This step ensures that the workstation is ready for the next user and
that order is sustained.

Standardise
Ensure uniform procedures and setups throughout the operation to promote
interchangeability.

Sustain
Ensure disciplined adherence to rules and procedures to prevent backsliding
SIX SIGMA
Lean
Identifying 'waste' or ‘non-
value-added activities’ from
the customer perspective and
then determining how to
eliminate it the 'right' way.
[Lean Six Sigma Institute]
Six Sigma
It Directly attacks the cost of
poor quality (COPQ)
The father of Six Sigma was Bill
Smith, a senior engineer and
scientist at Motorla
BUSINESS PLAN
Summary

Objectives Mission Success Factors

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BUSINESS PLAN
Highlights
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Business Plan
highlights

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 TALLER

MENCIONE EN QUE CASOS EN

UNA INDUSTRIA, SE PUEDE
APLICAR EL SMED.