Abstract
In this world of
competition without proper production management a company cannot survive.
Using a manufacturing concept for competitive advantage is relatively a new
concept.
Lean manufacturing is
a concept actually brought up y Toyota motor company, Japan. But it was
popularized to the world by the book “THE MACHINE THAT CHANGED THE WORLD” by
Womack, Jones and Roos of MIT in 1990.
Adding value by
eliminating waste, being responsive to changes, focusing on quality and
enhancing effectiveness of workforce is what achieved by lean manufacturing. It
needs a systematic and continuing search for non value added activities. This
seminar provides an overview of basic elements, techniques and benefits of lean
manufacturing.
Elements Of Lean Manufacturing
Those concepts that
lead to the implementation of lean manufacturing successfully are called
elements of lean manufacturing. The basic elements of lean manufacturing are
waste elimination, continuous improvement, pull system, one-piece workflow,
cellular manufacturing and 5S’s. When these elements are focused in the areas
of cost, quality and delivery, this forms the basis for a lean production
system.
Elimination Of Waste
Waste is anything
that doesn’t add value to the product. Seeing whether the process is adding
value to the product or not is the best way to identify wastes.
Is the activity adding value?
If YES If NO
Is this the best way to do it? Can it
be eliminated?
If not, can it be reduced?
Out of the complete
processes in an industry only about 5 % actually add value to the product. Rest
of the process does not add any value. Rest 35% activities are such that even
though this doesn’t add any value but still it cannot be eliminated as it is
necessary. For eg. Inventory cannot be
completely reduced, scrap materials cannot be made zero, it may take few
minutes to load unload and load for next operation etc. So focus should be on
complete elimination of waste activities and reducing the necessary non-value
adding activities
One-Piece Flow
One piece flow is one of the important
techniques in implementing lean manufacturing. Traditional batch production in
mass production is replaced by one piece flow in lean manufacturing. Here batch
size is reduced to almost one. This reduces the total lead time and also
reduces waiting between operations or queuing.
Comparison Between Traditional And
Lean Manufacturing
For years
manufacturers have created products in anticipation of having a market for
them. Operations have traditionally been driven by sales forecasts and firms
tended to stockpile inventories in case they were needed. A key difference in
Lean Manufacturing is that it is based on the concept that production can and
should be driven by real customer demand. Instead of producing what you hope to
sell, Lean Manufacturing can produce what your customer wants with shorter lead
times. Instead of pushing product to market, it's pulled there through a system
that's set up to quickly respond to customer demand.
Lean organizations
are capable of producing high-quality products economically in lower volumes
and bringing them to market faster than mass producers. A lean organization can
make twice as much product with twice the quality and half the time and space,
at half the cost, with a fraction of the normal work-in-process inventory. Lean
management is about operating the most efficient and effective organization
possible, with the least cost and zero waste.
Advantage
- High quality & reliability
- Lower overall costs
- Self-directed work teams
- Lead time reduction
- Fast market response
- Longer machine life
Conclusion
“LEAN” can be said as
adding value by eliminating waste being responsive to change, focusing on
quality and enhancing the effectiveness of the work force.
Although lean has its
origin in the automobile industry it is being successfully used in other
production industries. Lean manufacturing is now extended to fields like I.T,
service etc in order to reduce production cost and meet changing customer
needs.
Since lean is
completely customer oriented it is here to stay. It is also important as it emphasis
customer satisfaction.
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