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Lean is about doing more with
less: less time, inventory, space, labor, and money.
Lean manufacturing is about commitment to eliminating waste, simplifying procedures and
speeding up production.
The idea is to pull inventory through based on
customer demand. |
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Policy
Deployment
Policy deployment,
also known as Hoshin Kanri, is a structured Lean management system that aligns an
organization's long-term strategic goals with
daily operations...
More
Employee Involvement & Empowerment
– organizing
workers by forming teams and giving them
training and responsibility to do many
specialized tasks, for housekeeping, quality
inspection, minor equipment repair and rework;
allowing also them time to meet to discuss →
problems and find ways to improve the process
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Employee
Involvement and
→
Empowerment
– organizing workers by forming teams and
giving them training and responsibility to do many specialized
tasks, for housekeeping, quality inspection, minor equipment
repair and rework; allowing also them time to meet to discuss
→
problems
and find ways to improve the process
-
Reduced Setup Cost and
Times (for semi-versatile
machinery such as big stamping presses)
– from months to hours thus making
small-lot production economically viable; achieved by organizing
procedures, using carts, and training workers to do their own setups,
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Small-Lot
Production
– allowing higher
→
flexibility
and pull production (or
just-in-time manufacturing)
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Quality at the
Source –
→
total quality management (TQM)
and control; assigning workers, not inspectors, the
responsibility to discover a defect and to immediately fix it;
if the defect cannot be readily fixed, any worker can halt the
entire line by pulling a cord (called jidoka)
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Pull Production,
or Just-In-Time (JIT)
– the method wherein the quantity of work
performed at each stage of the process is dictated solely by the
demand for materials from the immediate next stage; thus
reducing waste and lead times, and eliminating inventory holding
costs
>>>
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Continuous
Equipment Maintenance
– as pull production reduces inventories,
equipment breakdowns must also be reduced; thus empowered
operators are assigned primary responsibility for basic
maintenance since they are in the best position do detect signs
of malfunction
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Multi- Skilled
Workforce
– as employees are empowered to do many
jobs, they must be provided with adequate training
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Supplier
Involvement
– the manufacturer treats its
supplier as a long-term partners; they often must be trained
in ways to reduce setup times, inventories, defects, machine
breakdowns, etc. in order to enable them to take responsibility
for delivering the best possible parts/services to the
manufacturer in a timely manner.
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