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Study of Select Issues in Lean Manufacturing

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Study of Select Issues in Lean Manufacturing Study of Select Issues in Lean Manufacturing Basant Chaurasia** IIMT Institute of Engineering & Technology, Meerut- 250001, Uttar Pradesh, India Prof. (Dr.) Dixit Garg Department of Mechanical Engineering, NIT, Kurukshetra, Haryana-136119, India Dr. Ashish Agarwal Department of Mechanical Engineering, IGNOU, New Delhi, India Dr. K.K. Garg, LLDIMS, New Delhi ABSTRACT In the existing global competitive market, offering high quality product with competitive cost is a challenging task for companies. In present paper a paradigm of lean production system focusing on its benefits has been presented. A conceptual framework of lean manufacturing showing benefits has been discussed. Lean manufacturing identifies and eliminates non value adding activities in design, production , supply chain management, order processing. This paper also analyzes ways to achieve leanness in manufacturing. It also investigates the overall impact of the benefits from lean manufacturing. The finding in the paper provides learning insights to readers about lean manufacturing. Keywords: Lean manufacturing; benefits; Impact; Issues INTRODUCTION The term ‘lean’ is first introduced in last two decade by Womack et.al. 1990 in their book “The machine that change the word”. Lean Manufacturing is an endeavor on doing right task, at right time, in right quantity to achieve relentless perfect work flow while eliminating waste with the flexibility and ability to change. Birth of lean was in Japanese company Toyota Corporation Taiichi Ohno started 1940s Toyota production system. HIGH QUALITY, LOWEST COST, SHORTEST DELIVERY TIME JUST IN JIDOKA (Visualize TIME Problem) PEOPLE- MACHINE PULL FLOW SEPARATION STANDARD TAKT TIME WORK KAIZEN ONE-PIECE FLOW 5S OPERATIONAL STABILITY (heijunka) STANDARD WORK Figure 1: The Lean House 2 tLingaya's Lalita Devi Journal of Professional Studies Study of Select Issues in Lean Manufacturing t3 Toyota Company got popularity in 1980’s for effective continuous flow process and focus to strive on added value to 2.5 Effective Communication System customer that was opposite to Henry Ford mass production system based on material resource planning (MRP) that was high Communication is defined as an interpersonal connection across tasks, with a limited time frame, for the purpose to define, volume production of standardized product with minimum product changeovers. conduct and control the transfer of information generated in one task to another .Communication is interaction between two The Lean “house” Diagram demonstrates how the Lean manufacturing can be foundation for improvement of Quality, parties .Either in form of e-mail, meeting, paper, phone, mobile, fax, social networking sites, internet, intranet or any form. It must Standardization of work & Satisfaction of customer. In past two decades Toyota production System has been studied by many of be clear and straight. researchers namely Adler, 1993; Womack and Jones, 1994; Liker, 1998; Sobek et al. 1998; Spear and Bowen, 1999; Mike Rother, 2009. Brox and Fader, 2002 defined just-in-time (JIT) production system as a manufacturing pioneer that identifies and eliminates 2.6 High Level of Customers Satisfaction all forms of waste from the system and strive for continual improvement. The follow on book, Lean Thinking: Banish Waste and Customer satisfaction is the measure of how product and services provide by the companies meet the customer expectation. Create Wealth in your Organization (Womack and Jones, 1996), tolds key steps of lean thinking Value, Value stream, flow, pull and Satisfaction is the customer fulfillment response, it is judgment of product or services feature or both itself provide pleasured level of perfection. fulfillment either partial or full (Oliver, 1997) 2. BENEFITS FROM LEAN MANUFACTURING 3. THRUST OF LEAN MANUFACTURING Lean manufacturing accelerate overall business performance this system configured of maximum flexibility and quick response resulting low inventory, reduction in lead time and high customer satisfaction. 3.1 Leadership The leadership within a manufacturing company plays an important role in sustaining the progress of lean concepts. The experts Increase Increase having relevant experience guide the less experience employee working for achieving leanness (Abdulmalek et.al., 2007). Productivity Profitability 3.2 Working Culture Environment The working culture of any manufacturing company determines the success of lean. The biggest problem in lean implementation is has been observed that no effort is done to priorities the importance of building a culture of prevention. Reduced Work in Streamline 3.3 5S Implementation Benefits Process Communication Inventory Implementing 5S in workplace, 5S stands short, set in order, shine, standardize and sustain. When companies introduced 5S as lean thinking, they ensure all unnecessary work tool and suppliers are removed (short), all necessary tools gets their specified place (set in order), work place is clean where work is performs (shine), cleaning methods are applies consistently (Standardize), continuously improve the practice of 5S. Causes to increase productivity is balanced flow, minimize waiting, walking and Reduced Highly unnecessary material handling activity, standardize task, visual control, team work, mistake proofing & zero error. Customer & Satisfied Production Customer 3.4 Continuous Improvement Process lead time To thrive and survive in highly competitive market scenario it is vital to increase and protect current profitability. Profitability of company increases due to measures and method of aspect related to product development, chain of supply, shop floor Figure 2: Benefits of lean manufacturing management and after sales service integration (Warneck et.al., 1995). Cost time investment (CTI) helps company how much 2.1 Reduction in Lead Time money tied up in process & how long for before recovered through sales with help of cost-time-profile (Revera et.al., 2007). Lean Lead time is the amount of time that elapses between when a process starts and when it is completed. Lead time is examined in profitability related to responsible autonomy in situation where people involved in developing procedure, adopt responsibility and Process industry, manufacturing sector, supply chain management and project management, where as companies want to reduce decision making authority transfers from higher to lower in order to reduce inventory, short cycle time, process flow based layout the amount of time it takes to deliver products into the market. In business process, lead time minimization is normally preferred. (Treville et.al, 2006) With the application of lean concept non value activities gets minimize which further results in reduction in lead time. 3.5 Streamlining Communication System 2.2 Reduction in Work in Process Inventory Communication is a key variable that affects the success rate in lean manufacturing implementation. Communication in any In lean manufacturing attempt is made to reduce the wastage. Raw material is introduced in the production process but is not yet a organization is important to share the information related to production, quality and suppliers. In the absence of communication finished product. Work in progress (WIP) therefore refers to all those materials and partly finished goods that are at different stages there may be a problem related to workers, quality and production (Worley and doolen, 2006.) of the production process. WIP exhibits inventory of raw materials at the starting of the production line cycle and finished products 3.6 Improving Customer Satisfaction Level inventory at the end of the production line cycle. Cost of work in process inventory causes increases the cost of product, cost of labour, cost of electricity etc. Lean manufacturing strive to be relentless in the elimination of all variability and waste and to ensure continuous improvement towards goal of customer satisfaction. Lean strategy was developing with customers, ownership group, Suppliers and employees. 2.3 Productivity Improvement Lean paramount is concern with safety of product through continuous improvement efforts, adoption of new quality process and In the simplest form, productivity is broadly defined as the relation between output produced and one or more associated inputs system that fulfill customer need and expectation. Lean enterprises continuously strive to achieve delivery time through that are used in production process (National Research council, 1979). Concept of productivity depends of objective of elimination of waste, reduced lead time and lowering work in process. measurement, data availability and researcher preference. Ratio is also measurement of efficiency so it can be also called productive efficiency. 4. OBJECTIVES OF LEAN MANUFACTURING 2.4 Improved Profitability 4.1 Smoothened Production Process It is the ratio of sales to cost that is equivalent to productivity multiply by Price recovery factor. In lean paradigm notion that take time precisely matches with production demand it improve dismal delivery performance of production process. Lean creates culture of continuous improvement, when process cycle of lead time decreases production This concept given by the American productivity centre. As the productivity increases profitability also increases. 2 tLingaya's Lalita Devi Journal of Professional Studies Study of Select Issues in Lean Manufacturing t3 Toyota Company got popularity in 1980’s for effective continuous flow process and focus to strive on added value to 2.5 Effective
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