The Importance Of Lean Manufacturing

Industries plays a vital role in Indian economy, it has emerged as a very important tool in providing relatively larger employment after agriculture. Global markets are continuously changing and demanding product of high quality with marginal cost. Such products can be produced using lean manufacturing, a philosophy that aimed to reduce wastes of manufacturing at all levels, so as to reduce product cost. Lean is about generating more values for buyers by eliminating activities that are regarded waste. Any activity or process that consume resources, time or adds cost without creating any value becomes the target for elimination. Lean Manufacturing is an efficient way to identify and eliminate waste through continual improvement. Lean is all about doing things in

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8. PDCA (Plan, Do, Check, Act) An unvaried methodology for implementing improvements:
• Plan (establish plan and expected results)
• Do (implement plan)
• Check (verify expected results achieved)
• Act (review and assess; do it again)
9. Poke-Yoke (Error Proofing)
Design error detection and prevention into production processes with the goal of achieving zero defects.
10. Root Cause Analysis
A downside finding methodology that focuses on resolution the underlying problem rather than applying fast fixes that solely treat immediate symptoms of the matter. a standard approach is to raise why five times – each time moving a step closer to discovering the true underlying problem.
11. Single Minute Exchange of Die (SMED)
Reduce setup (changeover) time. Techniques include:
• Convert setup steps to be external (performed while the process is running)
• Simplify internal setup (e.g. replace bolts with knobs and levers)
• Eliminate non-essential operations
• Create standardized work instructions
12. Standardized Work
Documented procedures for producing that capture best practices (including the time to complete every task). Must be “living” documentation that is easy to change.
13. Takt