Your boss has just come to you and told you that your company is now going in the direction of lean manufacturing so they can cut down on waste in the production process. Hearing this news, you realize you need to research lean manufacturing to determine what your company is doing.
What is lean manufacturing? Provide examples of companies using lean manufacturing and how it benefits them.
What are the requirements for balancing JIT (just in time) and lean systems?
Are any employees affected if a company decides to switch to a lean system? If so, which ones and why?
Is lean manufacturing a push or pull system? Explain.
Lean manufacturing is a system of manufacturing that reduces waste to the greatest extent possible. By reducing waste, management is able to accomplish a few different goals. The main goal is to reduce waste and therefore save money. When waste from the manufacturing process is high or anywhere above optimal levels of waste, it turns into a cost drain. All manufacturing processes incur waste, and by minimizing the waste, the company is able to save time, money, and resources through lean manufacturing.
Toyota was one of the first companies to successfully use lean manufacturing in their production process. By eliminating all areas where waste was present that were possible, and by reducing remaining areas that continued to produce waste to the lowest levels possible, Toyota was able to restructure their manufacturing to a point of extensive cost savings. Lean manufacturing also allows management to allocate additional funds to other areas where it is needed, like advertising, labor, or other areas of production. This is possible because of the cost savings that comes with the lowest possible level of waste in a production process.
The benefits are really endless of lean manufacturing. Lean manufacturing is a strategy, and by using the strategy, the entire production process becomes more effective. In addition, lean manufacturing reduces cycle time. The company can produce more in a shorter amount of time while reducing waste. Quality ...
This solution discusses lean manufacturing. We discuss several points, including its impact on the company, companies using lean manufacturing, the requirements of balancing JIT and lean systems, and how it affects employees. I also discuss if lean manufacturing is a push or pull system, and other related areas.
Lean Production System
John and Tripp at HMC know that the workforce, including both hourly and salaried employees, need to be brought up to speed on the concepts of lean production for the upcoming production changes to be successful. They want to start having plant meetings as soon as possible. For this to happen, the CEO John Michael, has asked you to prepare a presentation explaining the types of waste that a lean production system seeks to eliminate.
For this assignment, you must submit a presentation consisting of 10-12 PowerPoint slides (not including title and reference slides) with at least 50-100 words of speaker's notes per slide in which you explain the types of waste that a lean production system seeks to eliminate. For full-credit, you must address the following in your presentation:
- Explain what a lean production system is.
- Explain how a lean production system functions.
- Explain the types of waste that a lean production system seeks to eliminate.
- Explain how a company would go about eliminating certain waste.
- Provide at least 2 examples of companies that have used a lean production system to eliminate waste.
- Provide at least 2 examples of waste companies are trying to get rid of.
- Explain how a lean production system would be implemented at HMC.
Tips and Tricks
You should identify and describe the types of waste that a lean production system seeks to eliminate. There are seven categories or types of muds or waste (Ohno, 1998):
- Overproduction means to manufacture an item before it is actually required.
- Waiting is used to describe the time when goods are not moving or being processed.
- Transporting product between processes is a cost that adds no value.
- Inappropriate processing is using expensive high precision equipment where simpler tools would suffice.
- Unnecessary inventory or work-in-progress (WIP) is a direct result of overproduction and waiting.
- Unnecessary and/or excess motion can include bending, stretching, walking, lifting, and reaching.
- Defects result in rework or scrap.