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")
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Business Analyst Group is the empanelled Lean Manufacturing Consultant ( LMC) of Quality Council of India (QCI). QCI is the national apex body for accreditation under the ministry of industries and the National Monitoring and implementation unit of MSME for Lean Manufacturing. BAG has been working with manufacturing units of different industry sectors since the year 2007
Lean manufacturing is a management philosophy derived mostly from the Toyota Production System (TPS). Lean manufacturing or lean production, often simply "lean", is a systematic method for the elimination of waste ("Muda") within a manufacturing process. Lean also takes into account waste created through overburden ("Muri") and waste created through unevenness in workloads ("Mura"). Working from the perspective of the client who consumes a product or service, "value" is any action or process that a customer would be willing to pay for. Essentially, lean is centered on making obvious what adds value by reducing everything else. Lean manufacturing is renowned for its focus on reduction of the seven wastes to improve overall customer value.
The Micro, Small and Medium Enterprises (MSMEs) are a vital part of the Indian economy contributing to over 45% of industrial production and around 40% of the total exports. There are more than 13 million MSMEs in India employing about 31 million people, easily the single largest contributor in terms of employment generation in the manufacturing sector.
Under the Lean Manufacturing Scheme, MSMEs will be assisted in reducing their manufacturing costs, through proper personnel management, better space utilization, scientific inventory management, improved process flows, reduced engineering time and so on with application of LM techniques.
Despite constituting more than 80% of the total number of industrial enterprises and supporting industrial development, many MSMEs in India have problems such as
· Sub-optimal scale of operation
· Technological obsolescence
· Supply chain inefficiencies
· Increasing domestic and global competition
· Fund shortage
· Change in manufacturing strategies
· Turbulent and uncertain market scenario
Lean manufacturing is aimed at the elimination of waste in every area of production including
· customer relations
· product design
· supplier networks and
· factory management
The goal of Lean Manufacturing is to incorporate
· less human effort
· less inventory
· less time to develop products, and
· less space
to become highly responsive to customer demand, while at the same time producing top quality products in the most efficient and economical manner.
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