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Lean Manufacturing

Lean manufacturing’s main idea is to preserve value with less work (which equates to fewer expenses for the manufacturing company). Lean manufacturing is derived from the management philosophy of the Toyota Production System (TPS). The steady growth of Toyota, from a small company to the world’s largest automobile manufacturer has proven that lean manufacturing techniques are essential for growth.

Lean manufacturing processes have two main concepts: just-in-time and autonomation. Just-in-time is the theory that if production and sales flow smoothly and effectively then there will be no inventory on stock. Autonomation is achieved with a human touch. Machines and systems are designed to aid humans with what humans do best. An example would be to give machines the ability to know when they are malfunctioning and warn humans when malfunctions happen.¹ In a nutshell, lean manufacturing is, “Focused on getting the right things to the right place at the right time in the right quantity to achieve perfect work flow, while minimizing waste and being flexible and able to change."¹



1. Womack, James P., Jones, Daniel T., & Daniel Roos (1990). The Machine that Changed the World.

Categories within Lean Manufacturing

Toyota Production System

Postings: 111

A system that seeks to improve the efficiency of the manufacturing process first adopted and designed by Toyota.

Split-Plot Design

From the Article that you assisted me in understanding DOE. "Design of a factorial experiment with randomization restrictions to assess medical device performance on vascular tissue. " from BMC Medical Research doi:10:1186/1471-2288-11-75. Please assist in the following: Determine what type of situation this is and the type

Introduction to Design of Experiments

In the surgical department, find a situation in which DOE could be used. Determine which DOE situation type it is. Describe and discuss how DOE could be used to improve the situation or solve it. State your position about which DOE situation this is and support your position. References.

Lean Strategy: Case Study

See link ( for case study and answer the following. 1. What are the VSM and the Kaizen for #1 project in "Packaging and Shipping".? 2. What was the original situation and the specific activities that were done in the project #1? 3. What were the resul

Implementation of Lean Manufacturing

Controlling represents a very important function of management. Necessary at all levels and all aspects of the organization, controls should be applied to organizational design, planning, employee performance, etc., among many other functions. Different types of controls are applied at various levels of the organization includi

Lean Production and Employee Empowerment

Lean production relies heavily on the concept of employee empowerment. For example, Toyota Manufacturing is regarded as a leader in lean production. What are some of the benefits of employee empowerment? What are some of the disadvantages of employee empowerment? In your opinion, is employee empowerment a fad or a useful t

Plant Management II

Describe the following characteristics to be included in the plant management process: - Medium- and short-term demand forecasting techniques (moving average, etc.) - Manufacturing planning process (S&OP, etc.) - Medium- and short-term capacity planning alternatives (master scheduling, MRP, etc.) - Production activity/shop

Quality Control Tools

The quality manager has just conducted an audit at the facility. The condition of the maintenance shop has raised great concern. The shop is filthy with clutter everywhere. In his report, he noted that tools are scattered through the shop area, old parts are stacked all around the walls, and walking conditions are hindered. The

Harley Davidson: Challenges, successes, business functions

1) What challenges/opportunities have this company had to overcome/capitalize on? 2) What has made the company you have chosen successful today? Discuss value chain activities/improvements. Are they customer focused, quality focused, low-price leader focused? 3) Are the company?s business functions integrated? 4) Wha

Concepts of Capacity Management

What are the possibilities of spending some of the capital budget on a machine and or tools? What are ways of improving setup time, improving quality, increasing capacity, and determining EOQs? What would be a short-term and a long-term solution for this product line problem?

Lean Production Systems

Explain what a lean production system is, how it will function, and discuss the importance of a company having a lean production strategy. Identify the key elements of a lean production strategy, and discuss why each is an important ingredient to a lean production strategy. Provide an example of at least one company that has use

Food Manufacturing Company Project Proposal: Reily Foods

Identify a company in the food manufacturing industry and address the following for a project proposal: 1. Type of organization (e.g., manufacturing; do not include the actual name) 2. Primary nature of the work performed 3. Size (revenue and number of employees) 4. Location (where the organization typically conducts busi

Managerial Accounting Approaches

Chose two and write a factual opinion with examples: small paragraphs. Modern Management techniques and their relationship with or effect on accounting. Discussion: -Lean Manufacturing -TQM -Activity-based Management (Costing) -Environmental Management (Accounting) References or use your own: http://www.accoun

Productivity, Process Improvement and Lean Thinking

Choose one of the following types of organizations: Hospital, local bakery, generic family restaurant, generic convenience store (could be a franchised store), a company of your own choice Create a company of this type. Identify and discuss at least three productivity issues that this company faces. Include the various produ

Lean production philosophy

- Describe how managerial accounting is different from cost accounting. - Describe the lean production philosophy. - Compare and contrast accounting principles in lean production to those of typical production.

The Lowdown on Lean Accounting

Summary of article: The Lowdown on Lean Accounting van der Merwe, Anton; Thomson, Jeffrey. Strategic Finance 88. Ã?8 (Feb 2007): 26-33. The article criticizes the Lean Accounting movement. Summarize three of the author's arguments.

Materials Requirement Planning

Explain how push and pull handle the causes of variability in demand/consumption identified below. a) The welding machine breaks down soon after a shift starts work on pipe run that will take the full shift to install if all goes well. b) The consumption of pipe hangers is about half of what is expected over a 3 week period

Management Accounting for Traditional Productions

Discuss how lean versus traditional production might affect a management accountant trying to calculate a company's costs. How would the information a management accountant would use to determine company costs change depending on type of production?

Utilizing Lean in Service Industries

Utilizing Lean in Service Industries Lean methodology was developed by Toyota in its auto manufacturing. It has since been employed worldwide by manufacturing companies. But it can also be used in other types of businesses and industries. Discuss some ways that Lean can employed in service Industries such as banking, retail,

Difference between health care and manufacturing management

1.Explain the difference between health care and manufacturing operations management. How can health care service and manufacturing use the same concepts of operations management? Which applications?"health care or manufacturing?"is more difficult why? 2.Identify two goals of operations management in health care. How does the

Organizational Anlysis of Coca-Cola

Choose an organization that sells goods of some sort. Discuss: - History and background of the organization, also including the types of goods sold and industry in which the organization operates. - The organization's supply chain characteristics -- type of supply chain, negotiations strategies, performance of the supply c

Lean Production, Absorption Costing for Rayco, Inc.

See attached file for full problem. 'These statements can't be right' said Ben Yoder, president of Rayco, Inc. 'Our sales in the second quarter were up by 25% over the first quarter, yet these income statements show a precipitous drop in net operating income for the second quarter. Those accounting people have fouled somethin

Varible and absorption costing

Essex Company applies fixed manufacturing overhead costs to its only product on the basis of each year's production. Thus, a new fixed manufacturing overhead rate is computed each year. Required: 1. Compute the unit product cost for each year under: a. absorption costing b. variable costing 2. Prepare a contribution

SMED (Single-Minute Exchange of Dies)

How does the service (setup and changeover) procedures used for racing cars differ from that of regular auto servicing? Is there anything that can be learned from the difference? What does this query have to do with SMED?

Allocation of Fixed Costs

Based on the articles attached... Describe the process of allocation of IT costs. Do you agree with the approach? Why or why not? What is the purpose of the allocation? What are the benefits of the allocation? Compare and contrast ABC Costing and Lean Manufacturing. How is the decision making in this organizat