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lean manufacturing

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  1. [1]
    eng.alkurd
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    تاريخ التسجيل: Apr 2007
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    lean manufacturing

    Lean manufacturing

    · Lean manufacturing means produce more with less. less time, inventory, capital, resources and this can be accomplish by highlighting what needs to be changes to stream line over all production process.
    · Lean mfg is use to increase productivity, quality, customer service, profitability.
    · Lean mfg focus in total system efficiency and it don’t prefer one operation to another operation.
    · Benefits of lean mfg
    1. shorter cycle time
    2. higher quality
    3. excellent customer
    4. service lower production cost
    · Guiding lean principle is streamlined production flow and lean focus on small patch's down one piece in some case to smoothes production flow in the plant
    · To increase the capacity of the factory in traditional way we hire employees, buy equipments, build addition factory space but in lean mfg we increase the value add work(machining, welding, finishing and assemble) and reduce non value add work(inspection, setup time, repair and rework) and reducing the cycle time by use the techniques of make one move one or efficient layout . Cycle time is the total amount time of the production parts in the system
    · Most lean mfg systems use
    1. Visual management techniques to face and solve problem by using the color pins and lights
    2. standardize work by use symbol documentation of the process to kwon the employee are there do the right job
    · One of the most essential principle of line mfg is the concepts of pull refer to production control system pace in replenishment and we can use this system in inventory management by using some mechanisms like computerize system or pins
    · Another essential principle of line mfg is quality at the source means done the parts in good properties because if the defect discover in the early stages of production it don’t have high cost but if the defect reach to customer the there is add cast (warranty, recall, and replacement) if the quality improve the production cost reduce
    · Acceptance factor
    1. genuine commitment
    2. acceptable work pace
    3. training

  2. [2]
    indust_a
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    تاريخ التسجيل: Aug 2006
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    lean manufacturing

    [Lean manufacturing
    Introduction to lean manufacturing:
    How lean manufacturing can be used to achieve substantial competitive advantage?
    Lean manufacturing is a production philosophy, and it considered a way of mapping the overall manufacturing process from raw material to the finished product to the customer.

    It is called lean because these principles manufacturers to produce more with less (less time, less inventory and less capital), also with fewer resources.

    - Lean manufacturing focus on continuous flow from row material to a customer eliminating any other wastes.
    - It is successful in many industries as the principles of lean manufacturing are applied in both small and large companies.

    The wrong of mass production is:-economy of scale.
    -individual work stations and workers.

    But Lean examines the whole operations focusing in the total system efficiency, and challenges the economy of scale (the large of production run the lower of cost per unit).
    The flow of lean is focusing on small patches for smooth flow.

    Cycle time:Is the total amount of time the production material is in the system.

    Value added activity: small amount of time that adds value to the product.
    Non value added activity: Activities that do not add value to the product and not required by the process or the customer.

    Reducing cycle time require reducing non value added time as possible.

    Value added time: include:-machining.
    -stamping.
    -Welding.
    -Finishing.
    -Assembly.
    Non value added time:
    -Scheduling.
    -moving staging material.
    -Equipment setup.
    -inspection.
    -Repairing.
    -rework.
    -Idle time.
    So the principle flow is (make one move one) to reduce the cycle time.

    Visual management techniques
    Lean companies use visual management techniques to help employees to recognize problems quickly, and it takes many forms but all have the same goal (help to highlight problems so they are quickly fixed).
    Standardization:Standardized work procedures are provided in most cases by symbol documentations at each work station, so that employees can move from job to job and still being assured that they are doing the job right.

    Lean manufacturing approach:When manufacturers need to increase production output they hire more employees, buy equipment, build additional space.
    But lean takes different approach, it expands the value added time and reduces non value added time, additional employees are not hired new equipment not purchased.

    Flexibility of layout:Keeping the work place flexible provides easy layout changes.


    Applying pull system:Pull is a productive control system, based on replenishment, materials are transported only to replenish consumed by downstream process or a customer .includes cards, marked floor space, computerized systems.

    Quality at the source:
    -if defective part discovered immediately the cost in disruption is minimum.
    -if the part is found in the final inspection it is important for rework.
    -if the defective reaches the customer there are added cost due to replacement and warranty.

    Acceptance factors:
    -Genuine commitment.
    - Acceptable work pace.
    - Training.

    Benefits of lean manufacturing:
    1-Shrter cycle time.
    2- Higher quality.
    3-Excellent customer service.
    4-Lower production cost.[/LEFT]

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  3. [3]
    chieftainmech
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    تاريخ التسجيل: Apr 2007
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    chieftainmech
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    تاريخ التسجيل: Apr 2007
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