Cost Reduction through Lean Manufacturing


What is Lean Manufacturing?

Lean Manufacturing refers to a system of methods that emphasize identifying and eliminating all non-value-adding activities, i.e. waste, from a manufacturing or manufacturing support organization. Processes become faster and less expensive. Lean manufacturing is characterized by fast cycle times, just-in-time methods, little or no inventory, continuous flow, production leveling and reliable quality. Lean organizations are efficient, flexible and highly responsive to customer needs. Applied correctly, 20% improvement in productivity, 30% reduction in floor areas and 50% reduction in lead times are quite common.

Why Lean Manufacturing?

Global competition, declining margins, and fast changing customer needs have forced businesses to reduce time wasted in producing goods & services to meet customers needs. For survival, organisations have to constantly maintain their focus on providing customer value and strive for continuous improvement in their operations. Lean Manufacture helps to identify key success factors needed to radically reorganise your company in the changed business environment.

 

 
Programme Overview

Course Objectives

  • To trigger Lean thinking for cost reduction
  • To provide an understanding of 7 wastes
  • To familiarise with lean manufacturing techniques
  • To provide an understanding of the essentials for implementing lean manufacture

Who should participate?

Unit Heads / Plant Heads / HODs / Senior executi es of manufacturing organizations.

 
Course Outline
  • Seven Wastes

  • Lean Manufacturing techniques
    • 5 S, a place for every thing and every thing in its place.
    • Standardization of processes, Setting the platform for improvements.
    • Value Stream Mapping for highlighting existing wastes.
    • Heijunka - Leveling the demand - Takt time for smoother production.
    • Faster Set-ups, Smaller batches, Cellular Manufacture to reduce inventory.
    • Pull - Kanban System, for Just-in-Time Inventory.
    • Problem Solving, 5 Whys and Not 5 Whos.
    • Workers participation for continuous improvement.

  • Order of implementation, Kaizen Blitz

  • Change Management

  • Need for Top Management's Commitment

  • Case histories
 
 
Past participants
  • Auto Textiles
  • Cosmo Ferrites
  • Harita Seatings
  • HMT Machine Tools Ltd.
  • HMT Tractors Ltd.
  • Mahavir Spinning Mills
  • Max Speciality Products Ltd.
  • Mehta Engineering
  • Punjab Tractors Ltd.
  • Samtel Colours Ltd.
  • Secure Meters
  • TBRL
  • Vardhman Spinning & General Mills
 
 
Programme Details
 
Duration:
2 Days (Course is non residential)
 
Contact Details
 
Student Profile
   
Manish Sharma
DGM - Mktg. & Training
Mobile: +91-98554-06222,
E-mail: m_sharma@tqmbizschool.org
Vinod Bhardwaj
General Manager (MDP)
Mobile: +91-99148-11947,
E-mail: vinodbhardwaj@tqmbizschool.org
   
PTU's Gian Jyoti School of TQM & Entrepreneurship
B-102, Industrial Area, Phase VIII,
Mohali 160-059 (Punjab)
Phones: +91-172-223-6187, +91-172-654-1187
www.tqmbizschool.org