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Lean Production Systems

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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 used lean production as a competitive advantage. Describe how the integration of lean production strategy could assist a company.

Explain what a lean production system is and why a lean production strategy is important to a company. Identify and describe the following basic elements of a lean production system:
- Focus on the operator, continuous flow production
- Quality at the source
- A safe, orderly, and clean workplace
- A flexible, cross-trained team
- Visual workplace
- Standard work methods

Research and identify a current company that has used lean production as a source of competitive advantage and explain how that company used its supply chain as that source of competitive advantage.

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// This paper will help the reader to understand the lean production system. It will also emphasize on the basic element of the system and explain how this system helps in achieving competitive advantage with the help of an example. The following section will explain the meaning and importance of the system along with how it works in an organization.//

The assembly line methodology used by the company that focuses on elimination of wastes in order to provide quality products to its customers referred as lean production system. This system facilitates providing right products with right prices at a right place to the customers. Therefore, it is also known as just in time approach. This approach emphasizes on minimizing the inventory by manufacturing the products as customers ordered it. This facilitates meeting the customer requirements which in turn increases the satisfaction level of customers. In this method, different resources used for production is passed through the assembly line in small lots so as to improve and increase the efficiency and effectiveness of the workers (Dennis, 2007).

Transfer of products in small quantities across different stages of the process results in reduction of the cycle time of the production. This results in increase in the overall productivity of a company. This method also facilitates building and maintaining relationship with the suppliers so as to improve the supply chain as building of strong relations with suppliers helps to procure raw material and other resources at low cost, which in turn facilitates offering end products to customers at reasonable prices (Dennis, 2007).

Lean Production System is the most popular method to ensure the total quality management in the companies, specifically Japan. Lean production system helps the managers to eliminate the wastes from the manufacturing process which helps in smooth flow of products across different processes. This results in providing quality products to the customers at reasonable prices as the adoption of this method reduces the cost of production, which results in value addition to the customers. Adoption ...

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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.

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