Lean production is based on the logic that nothing will be produced until it is needed. Need is created by an actual demand for the product. When an item is sold, in theory, the market pulls a replacement from the last position in the system or final assembly. This triggers an order to the production line which generates orders at upstream work stations. Lean demands high levels o quality at each stage of the process, strong vendor relations, and a fairly predictable demand for the end product. | Chapter 12 Lean Production Lean Production Defined The Toyota Production System Lean Implementation Requirements Lean Services OBJECTIVES 2 Lean Production Lean Production can be defined as an integrated set of activities designed to achieve high-volume production using minimal inventories (raw materials, work in process, and finished goods) Lean Production also involves the elimination of waste in production effort Lean Production also involves the timing of production resources (., parts arrive at the next workstation “just in time”) 3 Pull System Customers Sub Sub Fab Fab Fab Fab Vendor Vendor Vendor Vendor Final Assembly Here the customer starts the process, pulling an inventory item from Final Assembly Then sub-assembly work is pulled forward by that demand The process continues throughout the entire production process and supply chain 4 Features of Lean Production Management philosophy “Pull” system though the plant WHAT IT IS Employee participation Industrial . | Chapter 12 Lean Production Lean Production Defined The Toyota Production System Lean Implementation Requirements Lean Services OBJECTIVES 2 Lean Production Lean Production can be defined as an integrated set of activities designed to achieve high-volume production using minimal inventories (raw materials, work in process, and finished goods) Lean Production also involves the elimination of waste in production effort Lean Production also involves the timing of production resources (., parts arrive at the next workstation “just in time”) 3 Pull System Customers Sub Sub Fab Fab Fab Fab Vendor Vendor Vendor Vendor Final Assembly Here the customer starts the process, pulling an inventory item from Final Assembly Then sub-assembly work is pulled forward by that demand The process continues throughout the entire production process and supply chain 4 Features of Lean Production Management philosophy “Pull” system though the plant WHAT IT IS Employee participation Industrial engineering/basics Continuing improvement Total quality control Small lot sizes WHAT IT REQUIRES Attacks waste Exposes problems and bottlenecks Achieves streamlined production WHAT IT DOES Stable environment WHAT IT ASSUMES 13 The Toyota Production System Based on two philosophies: 1. Elimination of waste 2. Respect for people 5 Elimination of Waste Focused factory networks Group technology Quality at the source JIT production Uniform plant loading Kanban production control system Minimized setup times 6 Minimizing Waste: Focused Factory Networks Coordination System Integration These are small specialized plants that limit the range of products produced (sometimes only one type of product for an entire facility) Some plants in Japan have as few as 30 and as many as 1000 employees 7 Minimizing Waste: Group Technology (Part 1) Using Departmental Specialization for plant layout can cause a lot of unnecessary material movement Saw Saw Lathe Press Press Grinder Lathe Lathe Saw Press Heat Treat Grinder
