Question

1. Explain the problem associated with the figure 1 and suggest method in how this problem can be rectified by using Lean Manufacturing techniques/tools. Figure 1

Answer 1

The word lean means to remove the unnecessary tasks from the process and to make the process efficient.In the given figure the items are not arranged properly and systematically and hence it's very hard and time consuming to search for a particular product.

PDCA (Plan, Do,Check and Act) is one of the step towards lean management. In this figure, we have to plan how to place the things like according to the variety, their usage on daily basis etc. Second we have to implement according to tthe plan. Third we have to Check on regular basis whether the items are in the place and the plan we decided works well. Fourth, we have to act if the the things are mismanaged we have to agin place them at the required position.

The 5S system is used to organize things placed in the shelf given:

1) Sort:The first step, ‘sort’ means to simply separate what is needed and necessary in the workplace or station. We can sort the items like bottles shown at one place, cards shown at another place.

2)Set:Everything in the work area has a place and is always stored there when not in use. So items are given places and they are set according to the daily requirements, weekly and monthly requirements.

3)Shine:The next step is ‘shine’ or ‘scrub’ to keep the work place clean by eliminating all forms of dirt, dust, grease and grime. All the items should be cleaned and maintained properly.Like in the image all the bottles must be cleaned. If there is any leakage from the bottles it should also be cleaned.

4) Standardize:Standardization creates a consistent way in which tasks and procedures are carried out so that absolutely anyone can understand the work. So the tags can be provided for individual types of products like bottles in one section,cards at another section.

5) Sustain: This step is to keep an eye whether all the previous steps are followed on regular basis in order to increase the efficiency and provide better results according to the usage.

Ans2)Kanban System also known as  pull method is used in lean manufacturing. It checks and ensures that material and products are pulled through the factory at the time when they are demanded . Kanban has been derived from Japanese word which means card.

kanban is a card or device which is used by a customer workstation to send a signal to the preceding supplier station that it needs more parts.It is one of the major component of JIT(Just In Time) production.There are three types of kanbans that are mainly used ,

1)Withdrawal kanban

2)Production ordering kanban

3)Supplier kanban

The U- shaped work cells has many advantages:
1)As the distance between the stations are shortened work can be shared between workers as well as there is reduction of transportation waste.

2)Communication is easier among team mates in the cell

3)As the space is less in U shaped cell as compared to traditional cell walk distances are reduced as they are

waste.

4)The IN and OUT gates are close,so there is easy visual control and management, so a  single person can handle both the cell input feeding and output.

5) Better flow and processing of product between various stations in a U shaped cell.