Basics of Lean Manufacturing

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What is manufacturing?

Manufacturing is a process that converts raw materials into useful products. This process may have many steps to make a product furnished by using machines, human labor, and other tools. Like socks manufactured after many processes implemented on the cotton.

What is lean manufacturing?

A lean product is a product that has these basic qualities that make it lean.

Lean manufacturing process diagram.

What is a product?

A product is an item manufactured for the betterment of humans and it can also be sold. All products are furnished from raw materials, are in machines, and have a cost.

What is Lean Production?

Production has these qualities which are given below called lean production.

  1. Fulfill Customer Requirements
  2. Deliver to the customer on Time
  3. Manufactured at Minimal Cast
  4. Manufactured in a Safe & Friendly Environment for employees.

Fulfill Customer Requirements

In today’s highly competitive market, the key to a successful business lies in fulfilling customer requirements with products of the highest quality. Product quality is not merely about meeting the basic specifications but involves exceeding customer expectations to foster loyalty and satisfaction.

We make a product that has the quality of “fulfills customer requirements” by implementing these techniques of lean manufacturing in our industry.

  1. Fulfill customer requirements
    • 1.1 Fault-free product
      • 1.1.1 Raw Material Faults
      • 1.1.2 Raw Material Combination
      • 1.1.3 Machine Knit Faults
        • 1.1.3.1 Fault Root Cause Analysis
    • 1.2 Quality Control
      • 1.2.1 Manufacturing Control Plan (MCP)
        • 1.2.1.1 Standardized Work
      • 1.2.2 Non-Conformity Report (NCR)
      • 1.2.3 Raw material & process Quality
    • 1.3 Actual Design
      • 1.3.1 Pattern Programming
      • 1.3.2 Sampling & Confirmation
    • 1.4 Size Variation
      • 1.4.1 Process for Resizing
    • 1.5 Product Policy
      • 1.5.1 Metal Free Product Policy
    • 1.6 Standardized Work
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Deliver on Time

2. Deliver on Time

  • 2.1 Material Supply Chain
    • 2.1.1 Raw Material Supply
    • 2.1.2 Inter-Section Material Transfer Advice (MTA)
    • 2.1.3 Order Devide into Batches
      • 2.1.3.1 Heijunka Batches System
    • 2.1.4 Bottle Neck Analysis
      • 2.1.4.1 Inter Section Stay Time Record
  • 2.2 Machines Performance
    • 2.2.1 Machine Maximum Utilization
    • 2.2.2 Number of Machines vs Order
    • 2.2.3 Overall Machine Efficiency
      • 2.2.3.1 Machine Downtime
      • 2.2.3.2 Machine Maintenance
      • 2.2.3.3 Categorize Machines
  • 2.3 Manpower Utilization
    • 2.3.1 Human Resource (HR) Policy
    • 2.3.2 Department Policy
      • 2.3.2.1 Performance Allowance
    • 2.3.3 Categorize Workers at Skill Base
  • 2.4 Goal-Oriented Tasks
    • 2.4.1 Keep Performance Indicator (KPI)
  • 2.5 Minimize Stay Time
    • 2.5.1 Pre Clear Product Root
    • 2.5.2 Manage Baches Traffic
    • 2.5.3 Blame to Responsible
  • 2.6 Use SMED Structure
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    Minimize Cast

    3. Industrial Cast Control System

    • 3.1 Control Wastes
      • 3.1.1 Product Waste Utilization
      • 3.1.2 Control 7 types of Wastes
      • 3.1.3 Categorize Wates
    • 3.2 Recycle/Reuse Waste
    • 3.3 Kaizens
      • 3.3.1 Ideas Sharing Strategy
      • 3.3.2 Effective Emprovements
      • 3.3.3 Kaizen Structure (PDCA)
    • 3.4 Corporative Pool
    • 3.5 Partially Automation
      • 3.5.1 Automation Department
      • 3.5.2 Automatic Dispencing Product (ADP)
      • 3.5.3 Machine Operation Automation
    • 3.6 Energy Saving Policy
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      Safe & Friendly Environment

      4. Create a Safe & Friendly Environment for workers

      • 4.1 Company policies
      • 4.2 Empowerment Culture
        • 4.2.1 Supervisors Training
          • 4.2.1.1 Skill Matrix Training
          • 4.2.1.2 Work Ethics Training
          • 4.2.1.3 Technical Training Center
        • 4.2.2 Transfer Responsibilities
      • 4.3 5s (Five S)
      • 4.4 EHS Rules
      • 4.5 Gamba Walks
      • 4.6 Audits
        • 4.6.1 Internal Audits
        • 4.6.2 External Audits
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