Lean Manufacturing Essay

Production practices have had an important role in satisfying the dynamic market. Many approaches have being developed in order to respond effectively to specific business requirements. In fact, some areas of management have focused its study on the overseeing, designing, and controlling the process of production in an effort to find the best methodology that ensures the business success and performance. However, complexities arise in this field because many variables such as costs, inventory, scheduling, suppliers, etc have to be considered in any business. Lean approach and the traditional approach are two points of view that aim to address this complexities, and those will be examined in this essay.

Lean is defines the manufacturing philosophy that reduces the time between the shipping and customer demand, which based on the systematic method by eliminating waste, that means giving the customer what they want when they want it, and don 't waste whatever. Rahmana, Sharif and Esa (2013) suggested lean production is mentioned to improve the company 's performance from the philosophy in reducing waste in order. That means, lean system destination is the decrease cost by removing the non-value activities, which they are applying a category of tools and techniques for checking and eliminating defective in the production process. In the Evenort Company should emulate the five overriding principles of lean thinking in terms of implementing lean that there is guarantee the company has been driving correctly in the lean manufacturing (Cardiff 2015) as can show in table 1.

The concept of Lean Manufacturing is well known and is being applied widely in industry. As industry moves forward in deploying lean concepts, it is important to recognize the potential benefit for attacking waste in above-the-shop-floor processes. While the benefits are significant in production, this typically constitutes less than 30 percent of the total cost of a product. Furthermore, the distributed, collaborative nature of manufacturing today depends extensively on efficient and cost-effective information processes among sites and throughout supply chains.

Abstract The ‘‘lean’’ approach has been applied more frequently in discrete manufacturing than in the continuous/process sector, mainly because of several perceived barriers in the latter environment that have caused

The core objection behind lean systems is to maximize customer value while minimizing waste. Basically, lean is defined by using fewer resources in order to make a perfect value for customers. How lean systems work, they use a highly skilled workforce and flexible equipment in order to make some advantages. Such as mass production which is the high volume and low unit cost. And craft production which is the variety and flexibility, this will help eliminate waste for the producer and consumer. Luckily, this approach has drawn attention to other services. For example, lean systems aren’t only suitable for manufactures but also health cares, offices and shipping and delivery. The misconception that lean is a tactic or cost reduction program is not necessarily true, but it is a process of thinking and acting for the entire company. In order to accomplish lean system thinking changes must refrain from management optimize separate technologies, assets and vertical departments.

This written review details the two articles chosen for week 8 topic, lean manufacturing. The first article, titled Lean Production Practices for Efficiency Kocakülâh, M. C., Austill, A. D., & Schenk, D. E, published in Cost Management 2011, details the multiple elements that make up lean programs. The second article, titled Manufacturing’s Oversized Claims McCullough, M, published in Canadian Business 2011, details some of the pitfalls and down side to Toyota Production System lean elements.

Lean System has become a popular technique used in both local and global markets. More companies are embracing it to improve efficiency, achieve better quality, and be more competitive. The Lean thinking was considered to be one potential approach to enhancing organizational performance. It has evolved into a management approach that improves processes at different levels of the organization. Nevertheless, the process of implementing lean manufacturing is bound to encounter obstacles. Besides defining the lean concept, this paper will consider the points that impede lean implementation and will outline the main two defies that companies are facing when they change their business model towards implementing a new management system, lean approach. This paper will also provide some recommendations to overcome these obstacles.

Lean operations and supply chain originated from the Toyota Production System in Japan and have influenced manufacturing over the past two to three decades. Lean is described as the product of applying the Toyota Production System to all areas of an industrial process. Toyota’s strategies are based on Just in Time manufacturing, continuous flow, reducing lead times, eliminating non-value added waste, and excess inventory, a pull system centred on customer demand and continuous improvement (Liker, 2004). These integrated processes became the basis of Lean manufacturing and have recently extended to include all aspects of the supply chain process. Raw materials arrive Just in Time for production based on the demand of the

Lean is a quality management program that was made popular at the Toyota Corporation. Its main philosophy involves eliminating wasteful or unnecessary steps in the process and creating value for customers. Toyota’s past president identified seven types of waste to be eliminated from the supply chain. They are waste from overproduction, wasting time, transportation waste, inventory waste, processing waste, waste of motion and waste from defects. Organizations that successfully implement Lean methodologies can reap dramatic benefits (Jacobs & Chase,

Lean manufacturing is an exercise that is based on waste minimization. It considers the utilization of resources for any activity other than the creating value for the customer, as waste. Basically, lean is centered on “Delivering value with less work by eliminating waste” (Liker, 1997). Lean manufacturing philosophy involves never ending efforts to reduce or eliminate 'muda' (Waste) in manufacturing processes.

In the twentieth century two major manufacturing revolutions have been introduced. Both revolutions have been developed at the automobile sector. The first revolution was mass production. In the 1900s the demand for cars has raised dramatically, and the automobile sector has become very competitive. Craft production has dominated the automobile sector; in fact using of the craft production was inadequate to manage the high demand at that period. In that

According to (Rouse, 2013), lean management is a method of running a business that supports the concept of constant improvement. Therefore, lean management is a long-term approach to work that thoroughly seeks to achieve small, incremental changes in processes in order to improve efficiency and quality. The theory was first established between 1948 and 1975 by Taiichi Ohno and Shigeo Shingo the two Japanese engineers (Arnheiter and Maleyeff, 2005). But the method was initially found in the works of Henry Ford, who “Ohno greatly appreciated and studied Ford because of his accomplishments and the reduction of waste at early Ford assembly plants” (Arnheiter and Maleyeff, 2005). Thus Lean management eliminates all forms of waste, decreasing errors, shrinking inventory and ordering or supplying parts “just-in-time,” therefore decreasing warehousing costs. (Rand, 2013) identified the seven forms of waste, including waste in unnecessary motion, over-processing and transportation. Thus by doing this it will saves the business money and allows workers to pay attention to more value-creating activities. There are four main principles of lean which are (Rouse, 2013) firstly defining the value from the perspective of the end customer, identifying each steps in a business process and eliminating non value activities, making the value-creating steps occur in tight sequence and then finally repeating the first three steps on a constantly basis until all the waste has been eliminated. The

The main aim of lean manufacturing is to limit inventory, excess workers and waste. The basic principles can be broken down into five practises – value, value stream, flow, pull and perfection [1]. It is essential to map the value that the product provides to the customer. Decisions need to be well thought-out, and implementations should be rapid. It is also important to ensure that each step provides value thus maintaining the value stream. Flow recognises the processes that ensure that the movement between the value creating steps is smooth. Lean manufacturing requires the customer to pull the output from the previous step and hence avoid overproduction. Finally, the vendor needs to continually strive to improve their quality and processes. Lean manufacturing emphasises on continuous improvement in quality and work should be stopped as soon as quality starts suffering.

“In academia, the majority of the operations management literature focuses on the application of lean manufacturing in large discrete organizations (Moreno-Luzon, 1993). [3] Few academic articles even started to raise interests over the straightforward application of lean manufacturing in processing industries (Abdulmalek and Rajgopal, 2007 &; Melton, 2005) [4]. The specific characteristic of goods and/or processes in processing industries offers a great demand to the application of lean manufacturing” (Abdulmalek et al., 2006; Van Donk and Van Dam, 1996) [5].

The Lean Manufacturing approach is meant to transform non-value added activity into value added activity. Lean Manufacturing technology has its impetus and focus on whole operation. Lean Manufacturing methods are inclusive of all employees and involve a major change in the embedded attitudes of the individuals that make up the organizations. In today 's highly competitive world, the Indian organizations are striving hard to