A Brief Description of the Case Study

2435 Words Mar 30th, 2006 10 Pages
A CASE STUDY IN LEAN MANUFACTURING

CONTENTS

A brief description of the case study………………………………………………. 2
Abstract………………………………………………………………………………………… 3
Lean Manufacturing………………………………………………………………………. 4
What is Kaizen?........................................................................................ 4
Garden State Tanning……………………………………………………………………. 5
Getting to Lean………………………………………………………………………….….. 6
Standard Tanning Industry Operations…………………………………………… 7
Teams are formed and new process flows are tried………………………… 7
Introduction to Kaizen (Continuous Improvement)………………………….. 8
Improvements in cutting leather…………………………………………………….. 9
Kanban Quantums………………………………………………………………………… 10
Results of becoming Lean
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For example, lean manufacturing depends on more frequent deliveries of smaller batches and alternate production items more often.[1]

The most important benefits of lean manufacturing are:

• Reduced Scrap & Waste
• Reduced Inventory Costs
• Cross-Trained Employees
• Reduced Cycle Time
• Reduced Obsolescence
• Lower Space/Facility Requirements
• High Quality & Reliability
• Lower Overall Costs
• Self-Directed Work Teams
• Lead Time Reduction
• Fast Market Response
• Longer Machine Life
• Improved Customer Communication
• Lower Inventories
• Improved Vendor Support & Quality
• Higher Labor Efficiency & Quality
[2]

What is Kaizen?

Kaizen is a Japanese word that means to "change for the good". Doing "little things" better everyday defines Kaizen- slow, gradual, but constant improvement- continuous improvement in any area that will eliminate waste and improve customer satisfaction.

Kaizen is what the Japanese did to the ideas they picked up from American manufacturers in the 1950s. the Japanese combined employee empowerment and Kaizen and then had everyone in their plants doing "little things" better everyday. Kaizen is the most powerful tool in the Japanese manufacturing arsenal. The target of Kaizen is cost reductionthrough the elimination of waste at all levels in the manufacturing process.

The definition of Kaizen has grown to mean something
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