Lean Manufacturing concepts are being applied to a variety of industries. These concepts ensure streamlined processes through a systematic analysis of wastes and elimination, while enhancing value. This book offers fundamentals, theoretical concepts, case studies, and examples, along with insights for lean integration in Industry 4.0.
The book offers a comprehensive coverage of topics in Lean Manufacturing which includes lean elements and tools, performance measures, project selection, integration, along with other related strategies. It ensures a balance between theory and practice of Lean Manufacturing by including the implementation aspects of lean tools. The book will explore insights for Industry 4.0 related to lean concepts and provide details on how they relate. Illustrations and examples depicting OEE (Overall Equipment Effectiveness) analysis and value stream map analysis are included. The book also provides case studies on lean manufacturing covering value stream mapping, project selection, and performance measurement.
Lean Manufacturing: Fundamentals, Tools, Approaches, and Industry 4.0 Integration can be used as a reference for academic researchers and industry practitioners. Undergraduate and postgraduate students can use it for a course on Lean Manufacturing. Doctoral students can also refer to it for advanced concepts, and industry practitioners can use it for practical insights.
Author(s): S. Vinodh
Publisher: CRC/Focal Press
Year: 2022
Language: English
Pages: 132
City: Boca Raton
Cover
Half Title
Title Page
Copyright Page
Dedication
Table of Contents
Preface
Acknowledgments
Author Biography
1 Introduction
1.1 Manufacturing Systems Transition
1.2 Origin of Lean Manufacturing
1.3 Definition and Concepts of Lean Manufacturing
1.4 Comparison of Mass and Lean Manufacturing
1.5 Summary
2 Lean Principles and Waste Categories
2.1 Lean Principles
2.2 Muda, Muri, and Mura
2.3 Waste and Waste Categories
2.4 Waste Analysis
2.5 Kaizen
2.6 Summary
3 Elements of Lean Manufacturing
3.1 Overview on Elements
3.2 Discussion on Elements (Value
Stream and Value Flow)
3.3 Activity Categorization in Value Stream
3.4 Push and Pull Production
3.5 Stability, Standardized Work, and SOPs for Lean System
3.6 Visual Management and Single-Piece Flow Concepts
3.7 Summary
4 Basic Lean Tools (5S and TPM)
4.1 5S Lean Tool
4.2 5S Implementation
4.3 Total Productive Maintenance – Overview and Pillars
4.4 OEE Analysis
4.5 TPM Implementation
4.6 Summary
5 Basic Lean Tools (VSM and Workcell)
5.1 Overview on Process Mapping and Value Stream Mapping (VSM)
5.2 VSM Terminologies and Data Types (Observation/Measurement, Computation Data)
5.3 Construction Steps of Value Stream Maps
5.4 VSM Illustration and Case Study
5.5 Variants of VSM (Advanced Models of VSM)
5.6 Workcell
5.7 Case on Lean Tools Selection
5.8 Summary
6 Supporting Lean Tools and Concepts
6.1 Scope of Supporting Tools
6.2 Description of Core Supporting Tools (Poka Yoke, Kanban, Autonomation, Visual Communication, and SMED)
6.3 Optimized Production Technology, Leveled Production, and Enterprise Resource Planning
6.4 Summary
7 Project Selection and Training for Lean Implementation
7.1 Importance of Project Selection
7.2 Project Selection for Lean Implementation
7.3 Training and Implementation for Lean
7.4 Lean Implementation Levels
7.5 Summary
8 Lean Performance Measurement
8.1 Lean Performance Measures
8.2 Assessment Approaches
8.3 Case Study on Leanness Assessment
8.4 Summary
9 Lean Integration with Other Strategies
9.1 Lean Six Sigma
9.2 Lean and Agile Manufacturing
9.3 Lean Sustainability
9.4 Summary
10 Lean Integration with Industry 4.0
10.1 Need and Scope of Integration
10.2 Insights on Lean and Industry 4.0
Integration
10.3 Analysis of Workforce Attributes for Lean and Industry 4.0
10.4 Summary
11 Research Issues in Lean Manufacturing
11.1 Application Domains in Lean Manufacturing
11.2 Research Avenues in Lean Manufacturing
11.3 Summary
Index
