1. Lean Production (MUDA)
Ijaz Ul Hasan
NPO Pakistan

2. Why we produce ? ? ?

3. What is Lean Lean = waste-less
Waste = non value-added = MUDA in Japanese
Productivity =
Maximize “Productivity”
 Minimize “Input”, if “output” is fixed
 Constant “Input”, more “output” 
Output
Input

4. Wastages (MUDA) Input ? ? ? ? What Else ???????????? Machines
Man (Human Resources)
Material
Method
Money
What Else ????????????
Wastages (MUDA)

5. Wastages (MUDA)
Any activity or process that adds costs but adds no value (for the customer).
There are a lot of “MUDA” in our business.
Do not miss (even) small “MUDA”
To realize “Lean”  “Kaizen” is mandatory
Kaizen by Genba + Management support

6. Non Value Added (Wastages)
Transportation
Inventory /WIP
Motion
Waiting
Over Production
Over Processing
Defect
Not used creativity of employees

7. Transportation
Unnecessary movement of information, products or components from one area to another.
Unnecessary transport usually occur together with unnecessary movement, product damages, lost parts and systems, which detect movements.

8. Before: 546 feet After: 222 feet
Transportation of main part of one of the Agri Implement
100 ft
10 ft
5 ft
10 ft
65 ft
10 ft
136 ft
Before: 546 feet
25 ft
55 ft
50 ft
After: 222 feet
80 ft W E

9. Difficult to transport in our local industry

10. Follow the bouncing paperwork

11. Inventory/WIP
Inventory is the quantity of items on stock, which are required to manufacture a product. These goods also cause costs to the company.
When they are not used they utilize valuable warehouse space, may become obsolete and may require raw materials, which cannot be used for more important goods.

12. Competitive organizations make sure that their system controls the inventory, so that money is not being wasted on unwanted items or build groups.

13. Lowering Inventory Reduces Waste
Scrap
Work in process inventory level (hides problems)
Unreliable Vendors
Capacity Imbalances
The analogy presented in this and the next four slides may help to illustrate the action of inventory in hiding problems.

14. Lowering Inventory Reduces Waste
Scrap
Reducing inventory reveals problems so they can be solved.
Unreliable Vendors
Capacity Imbalances
WIP

15. Lowering Inventory Reduces Waste
Scrap
Reducing inventory reveals problems so they can be solved.
Unreliable Vendors
Capacity Imbalances
WIP

17. Motion
Unnecessary movements occur when employee is moving around his work space and as a result of this may waste time and effort.
All kind of unnecessary motion is being caused by poor working standard  practices, poor (not optimal) process design or  work area layout.

19. The crouching posture is MUDA of motion
I can take it easily
The crouching posture is MUDA of motion
Parts rack Up
Before improvement
After improvement

21. Waiting
Each step  in a manufacturing process is dependent on the  upstream and downstream stage processes.
If employees, equipment, information or materials of the production process are delayed, production time is wasted and the cost of production will be increased.

22. Turner operating two machines now
Waiting eliminated
Turner operating two machines now

23. Over Production
Overproduction arises when the company is producing more than the customer really requires.
This may include both the production of products or components for which there are no orders, as well as production of more items than currently needed.

24. Over Production
This is the worst kind of waste, because it usually multiplies other kinds of waste. It increases rework rate, inventory, processing, waiting, as well as unnecessary motion and transportation

26. Over Processing
Over processing includes extra steps in the manufacturing process which need to be taken.
It can also mean producing products of a higher quality than required. This may be due to incorrectly used equipment, errors in rework process, poor process design or bad communication.
This can be also result of not checking what are the real customers’ requirements.

27. Example

28. Non Conformance (Defects)
Rework is required when products and components are defective or damaged and they have to be reworked.
Defects are caused by bad manufacturing processes (caused by human or machine errors).
Rework takes additional time and therefore increases manufacturing costs of the final product. In worst case scenario the items have to be discarded.

29. Un Controlled Process Defects occur due to
Owner/manager has no training in this process!
Mishandling
Lack of Knowledge Inputs

30. Not Used: Creativity Of Employees
This waste involves loss of time, skills, ideas, improvements and learning opportunities by not taking employees opinion into the account.
This is result of employees not taking part in design of manufacturing processes. Only in this way the ideas can develop, which are needed to eliminate and avoid the other seven sources of waste.
This  helps to improve your processes in continuous manner by increasing the available knowledge and creativity of you employees.
In addition it helps in principle to increase the level of employees’ satisfaction at work.

31. People who work in the process and know the process best (both the strengths and weaknesses).
Do they have the tools, training and permission to systematically improve their process?

32. Thanks