Lean Manufacturing


Lean Manufacturing is a manufacturing philosophy and those concepts exist since last 50 years in the world. This is some kind of waste reduction process in the value stream map. There are lots of companies achieved huge benefits through lean manufacturing concepts. “Toyota” is the main achiever through lean. Currently most organizations try to implement lean manufacturing concepts in the world as well as in Sri Lanka. Under lean manufacturing we are doing following things.

01.Basic introduction of lean manufacturing
Through this program we provide some basic idea about this concept and analyze the improvement opportunities in your organization for development.

02.Value stream mapping
Through this program we identify value adding percentage of your process by drawing value stream map (VSM). Then provide advices to improve the value adding percentage by reducing or eliminating Non value adding activities. This program lead to reduce your processes lead time and it will help you to enhance the quality of product, reduce the cost of manufacturing and enhance the ontime delivery status.

03.Reduction of waste in manufacturing
One of the key steps in Lean is the identification of which steps add value and which do not. By classifying all the process activities into these two categories it is then possible to start actions for improving the former and eliminating the latter. Once value-adding work has been separated from waste then waste can be subdivided into 'needs to be done but non-value adding' waste and pure waste. The clear identification of 'non-value adding work', as distinct from waste or work, is critical to identifying the assumptions and beliefs behind the current work process and to challenging them in due course.
There are seven wastages in manufacturing.


Each time a product is moved it stands the risk of being damaged, lost, delayed, etc. as well as being a cost for no added value. Transportation does not make any transformation to the product that the consumer is willing to pay for.


Inventory, be it in the form of raw materials, work-in-progress (WIP), or finished goods, represents a capital outlay that has not yet produced an income either by the producer or for the consumer. Any of these three items not being actively processed to add value is waste.


In contrast to transportation, which refers to damage to products and transaction costs associated with moving them, motion refers to the damage that the production process inflicts on the entity that creates the product, either over time (wear and tear for equipment and repetitive stress injuries for workers) or during discrete events (accidents that damage equipment and/or injure workers).


Whenever goods are not in transport or being processed, they are waiting. In traditional processes, a large part of an individual product's life is spent waiting to be worked on.


Over-processing occurs any time more work is done on a piece than is required by the customer. This also includes using tools that are more precise, complex, or expensive than absolutely required.


Overproduction occurs when more products is produced than is required at that time by your customers. One common practice that leads to this muda is the production of large batches, as often consumer needs change over the long times large batches require. Overproduction is considered the worst muda because it hides and/or generates all the others. Overproduction leads to excess inventory, which then requires the expenditure of resources on storage space and preservation, activities that do not benefit the customer.


Whenever defects occur, extra costs are incurred reworking the part, rescheduling production, etc. This results in labor costs, more time in the "Work-in-progress". Defects in practice can sometimes double the cost of one single product. This should not be passed on to the consumer and should be taken as a loss.
Actually this is very time consuming project and need some cultural change to reduce above wastes. We can guide you for waste elimination.

04. 5S & Visual Factory

5S is the name of a workplace organization method that uses a list of five Japanese words: seiri,seiton,seiso,seiketsu, and shitsuke.Transliterated or translated into English, they all start with the letter "S". The list describes how to organize a work space for efficiency and effectiveness by identifying and storing the items used, maintaining the area and items, and sustaining the new order.
Visual management is one of the lean techniques designed so that anyone entering a work place, even those who are unfamiliar with the detail of the processes, can very rapidly see what is going on, understand it and see what.
We provide consultant to implement 5S concept and Visual management concepts. Through these concepts you can make your organization’s appearance well and create foundation for system driven culture.

05.What is Andon systems and benefits of Andon systems

Andon is a manufacturingterm referring to a system to notify management, maintenance, and other workers of a quality or process problem. The centerpiece is a signboard incorporating signal lights to indicate which workstation has the problem. The alert can be activated manually by a worker using a pull cord or button, or may be activated automatically by the production equipment itself. The system may include a means to stop production so the issue can be corrected. Some modern alert systems incorporate audio alarms, text, or other displays.

We provide you guidance to select the Andon system and how to install after conduct your processes and feasibility study.

06.In Station Quality (ISQ)

Now most of the organizations try to reduce quality carder by giving responsibility to process owners. Actually correct concept is producer need to assure the quality of their production. Through this concept we lead you to start quality assurance process at the source.

07.Work Standardization

Standardized work is one of the most powerful but least used lean tools. By documenting the current best practice, standardized work forms the baseline for kaizen or continuous improvement. As the standard is improved, the new standard becomes the baseline for further improvements, and so on. Improving standardized work is a never-ending process.
Basically, standardized work consists of three elements:
•Takt time, which is the rate at which products must be made in a process to meet customer demand.
•The precise work sequence in which an operator performs tasks within takt time.
•The standard inventory, including units in machines, required to keep the process operating smoothly.
We can guide and create Standard Operation Sheets for your requirements. We are doing individual operation standardization as well as Process standardization.

08.Quick Changeover (QCO) / Setup Reduction

QCO is one of the many lean production methods for reducing waste in a manufacturing process. It provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product. This rapid changeover is key to reducing production lot sizes and thereby improving flow (Mura).
Setup time is big issue for every manufacturing organization. We can work with you to reduce your organizations setup times.

09.Total Productive Maintenance (TPM)

Total productive maintenance (TPM) originated in Japan in 1971 as a method for improved machine availability through better utilization of maintenance and production resources.
Whereas in most production settings the operator is not viewed as a member of the maintenance team, in TPM the machine operator is trained to perform many of the day-to-day tasks of simple maintenance and fault-finding. Teams are created that include a technical expert (often an engineer or maintenance technician) as well as operators. In this setting the operators are enabled to understand the machinery and identify potential problems, righting them before they can impact production and by so doing, decrease downtime and reduce costs of production.
We have capability to introduce TPM activities to your organization.

10.KAIZEN & Continuous improvement concepts

Continuous improvement process is an ongoing effort to improve products, services, or processes. These efforts can seek "incremental" improvement over time or "breakthrough" improvement all at once.Delivery (customer valued) processes are constantly evaluated and improved in the light of their efficiency, effectiveness and flexibility.
We have experience to train you regarding the Kaizen activity and continuous improvement projects.

11.Quality Circles & PDCA Concept

PDCA (plan–do–check–act or plan–do–check–adjust) is an iterative four-step management method used in business for the control and continuous improvement of processes and products. We can use this concept to solve the repetitive problems which create barriers to achieve the organizational goals. We can guide & consult you to solve problems through PDCA concept.

12.5 Why & Root Cause Analysis

In any kind of Organization, there are lot problems raise in their process. Day to day management provide solutions for those problems. However if those problems occur again and again, we can assume given solution was not perfect. If we need to give proper solution, we need to find the root cause. We can train you to find the root causes through this concept.