1. Lean
production
Müge umut

2. OUTLINE What is lean production? Principles of Lean
TPS (Toyota Production System)
Types of wastes-muri,mura,muda
Steps to achieve lean systems

3. Lean production is the systematic elimination of waste overproduction,waiting,transportation, inventory motion,over processing,defective units and the implementation of the concepts of continuous flow and customer pull.

4. Lean is centered on preserving value with less work.

5.
Principles of lean

6. Specify value from the standpoint of the end customer by product family.
Identify all the steps in the value stream for each product family, eliminating whenever possible those steps that do not create value.

7.
Make the value-creating steps occur in tight sequence so the product will flow smoothly toward the customer.
As flow is introduced, let customers pull value from the next upstream activity.

8. As value is specified, value streams are identified, wasted steps are removed, and flow and pull are introduced, begin the process again and continue it until a state of perfection is reached in which perfect value is created with no waste.

9. TOYOTA PRODUCTION SYSTEM -TPS-

10. Lean production is an assembly line methodology developed originally for Toyota and the manufacturing of automobiles. It is also known as the Toyota Production System(TPS) or just- in-time production.

11. Taiichi Ohno is credited with developing the principles of lean production after World War II.
His philosophy, which focused on eliminating waste and empowering workers, reduced inventory and improved productivity.
-Taiichi Ohno-

12. Toyota has four rules for TPS. These rules are:
Clearly specify all activities:content,sequence,timing,outcome
Clearly define all connections to every customer and supplier: direct,yes or no answers

13. Clearly define all pathways: simple, direct steps to deliver the requested product or service
Continuosly improve: direct response to any problem that arises,by those doing the work – as close to the problem as possible,whenever possible start as an experiment,supported coach.

14. Types of wastes: muri mura muda

15. The elimination of waste is the goal of Lean, and Toyota defined three broad types of waste muda ,muri and mura.
Muda is non-value-adding work,muri is overburden,mura is unevennes. Waste reduction is an effective way to increase profitability.

17. The seven muda are:
Transport (moving products that is not actually required to perform the processing)
Inventory (all components, work in process and finished product not being processed)
Motion (people or equipment moving or walking more than is required to perform the processing)

18. Waiting (waiting for the next production step)
Overproduction (production ahead of demand)
Over Processing (resulting from poor tool or product design creating activity)
Defects (the effort involved in inspecting for and fixing defects)

19. And a few more types of wastes:
Confusion missing or misinformation.Confusing goals and metrics.
Unsafe or unergonomic work condition
Underutilized human potential like skills,talent,creativity.

20. There is a second approach to Lean Manufacturing, which is promoted by Toyota, in which the focus is upon improving the "flow" or smoothness of work, thereby steadily eliminating mura ("unevenness") through the system and not upon 'waste reduction' per se.

21. Mura is avoided through just in time (JIT) systems which are based on little or no inventory, by supplying the production process with the right part, at the right time, in the right amount, and first-in, first out component flow.

22. Muri (unreasonable)  is a Japanese term for overburden, unreasonableness or absurdity, which has become popularized in the West by its use as a key concept in the Toyota Production System.

23. Muri can be avoided through standardized work
Muri can be avoided through standardized work. To achieve this a standard condition or output must be defined to assure effective judgment of quality.
Then every process and function must be reduced to its simplest elements for examination and later recombination.
The process must then be standardized to achieve the standard condition. This is done by taking simple work elements and combining them, one- by-one into standardized work sequences.

24. In manufacturing, this includes:
Work Flow, or logical directions to be taken,
Repeatable Process Steps and Machine Processes, or Rational methods to get there, and
Takt time, or reasonable lengths of time and endurance allowed for a process.

25. Continuous improvement Just in time Theory of constraints
TPS has been used for the performance improvement of various systems. The following names are used for “systems improvement” interchangeably:
Kaizen
Lean thinking
Flow
Continuous improvement
Just in time
Theory of constraints
Quality circles
Six sigma
Total quality management
Total productive maintanence.

26.
TPS HOUSE

27. TPS house summarizes the fundamentals of TPS
TPS house summarizes the fundamentals of TPS. JIT and JIDOKA are the pillars of this house. The room of the house involves the methods like 5S,SMED etc.

28. Steps to achieve lean systems
The following steps should be implemented to create the ideal lean manufacturing system:
Design a simple manufacturing system
Recognize that there is always room for improvement
Continuously improve the lean manufacturing system design