Lean manufacturing or lean production, often simply "lean", is a systematic method for minimization of 8 wastes ("Muda") within a manufacturing system without sacrificing productivity.
8 classical wastes of a manufacturing unit are
Lean also takes into account waste created through overburden ("Muri") and waste created through unevenness in workloads ("Mura")
Lean Manufacturing process considers the use of the resources for any other purpose other than the value addition as a waste and considers it for elimination. The training modules stress for exceeding your goals and expectations focuses on the optimum utilization of every resource available and discourages the wastage of any of the resources. The motto is this process is to preserve the value with minimum work. It leads to a lot of improvement in the customer value and reduces the costs incurred by the company leading to higher profits to the company.
What is 5S
training / workshop on 5S & Kaizen at your workplace
5S represents Japanese words that describe the steps of a workplace organization process.
English equivalent words are also shown below
1. Seiri (Sort)
2. Seiton (Set in order)
3. Seiso (Shine)
4. Seiketsu (Standardize)
5. Shitsuke (Sustain)
In simple terms, the five S methodology helps a workplace remove items that are no longer needed (sort), organize the items to optimize efficiency and flow (set in order), clean the area in order to more easily identify problems (shine), implement colour coding and labels to stay consistent with other areas (standardize) and develop behaviours that keep the workplace organized over the long term (sustain).
5S is a team run process and should be conducted by the people who work within the area in which the principles of 5S are being applied, it is not a tool that can be applied by an outsider onto an area without the knowledge and cooperation of the people within it.
What is Kaizen
Kaizen is a lean manufacturing tool that improves quality, productivity, safety, and workplace culture. Kaizen focuses on applying small, daily changes that result in major improvements over time.
Kaizen first surfaced during the effort to rebuild Japan after World War II. At the time, several U.S. business consultants collaborated with Japanese companies to improve manufacturing. The collaboration resulted in the development of several new management techniques, one of which was Kaizen. Kaizen comes from two Japanese words Kai (improvement) and Zen (good). Over time, it became widely known as "continuous improvement."
Unlike many business practices, Kaizen's strength comes from requiring all workers-from the CEO to the shop floor assistant-to participate by making suggestions to improve the business
Total Quality Management (TQM) is a management framework based on the belief that an organization can build long-term success by having all its members, from low-level workers to its highest ranking executives, focus on quality improvement and, thus, delivering customer satisfaction.
It is a work group of employees who meet regularly to discuss their quality problems, investigate causes, recommend solutions, and take corrective actions. Generally, QC is a small group of employees belonging to the same / similar work area.
This is so because the employees doing the similar type of work are well familiar to problems faced by them. The size of the QC should not be too big so as to prevent some members from participating meaningfully in its meetings. Generally, six to eight members are considered the ideal size of the QC.
Objective of Techno-Economic Feasibility Report (TEFR) and Detailed ProjectReport(DPR) is to determine the technical feasibility and financial viability of the project, assess the risks associated with the project and enumerate imminent actions that are required to be taken.
TEFR & DPR covers the followings
Exploratory Research on the product
Market Study for Market Assessment
Infrastructure & site selection
Broad Market Assessment
Infrastructure and Site Selection
Manufacturing Process and Technical Concept
Electrical, Instrumentation and Control System
Civil Engineering Considerations
Manpower Requirement and Training
Project Implementation Schedule
Assessment of Capital Cost
Cost of Production and Profitability
Investment and Financial Analysis