Lean Production Of Lean Manufacturing

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.

Under the lean production approaches, a number of factors are essential to the process for

Countess firms have taken up lean production in their manufacturing process. This is because the process is known to have countless benefits when effectively implemented. For lean production to be effectively implemented, some principles have to be considered. These principles have been discussed in detail in this paper. The different principled in lean production as well as the different principles in effective business communication. How they are related and hence how they lead better production and hence better output from the firm.

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.

One obstacle is the perception that the use of lean manufacturing solutions is, at best, nothing more than a trend. In addition, at worst, a brief craze. It is often observed as nothing more than a repackaging of fundamental industrial engineering principles dressed up in new clothes, and flaunted in new terms to appeal to a new industry. Lean manufacturing is sometimes seen in many industries as a collection of techniques, known to be effective in the auto industry, which some people are now trying to impose on a completely different industry. This means that perceptions have to be changed.

The system of interconnected businesses used to push a product from supplier to consumer is defined as a supply chain. Supply chain management focuses on managing the supply chain in an effort to improve the quality and time it requires to manufacture a product. To implementing supply chain management, a helpful lean production practice called Just-in-time can be used to remove any waste present along the supply chain. The marriage of lean production and supply chain management creates lean supply chain management, which provides a much leaner and more economical supply chain for the product to flow through.

Nowadays, Lean management is one of the most well-known operation management in the world. According to Lean enterprise Institution, it said that the philosophy initially integrated by henry ford, however, at that time the system is still not perfectly done. The problem with ford is that he could not provide the variety. Then after the world war, Kiichora Toyota has look to fix that that problem by using some series of simple innovation to helping the issues and invented the Toyota production system which is the initial concept of lean which is the operation system that help Toyota to become the largest automaker of the world. Then, James P. Womack who was also known as father of lean production and as management expert, founder and senior

At this point, Toyota was operating in an environment that had limited resources when it comes to land as well as technology, ironstone and financial investments. These specific circumstances made Toyota redefine efficiency in their own way, and come up with new ground principles in order to cope with the scarce resources. The basic idea of Lean is to focus on flow efficiency instead of resource efficiency and to focus on the customer, producing only what the customer wants, in the amounts the customer wants it, and at the time the customer wants it (Larsson, 2008). Lean developed to be a set of principles, practices, tools and techniques focused on reducing waste, coordinating workflows and handling variability (de Koning et al.,

The basic concepts involved in lean and lean manufacturing was originated from The Toyota, one of the Japanese automaker in the global competition since decades. In 1988, Taiichi Ohno brought the lean concept into operation for the first time at Toyota and called it as Toyota Production System (TPS), to overcome economic crisis due to World War II. TPS was mainly developed to flourish with minimum resources. Owing to the immense shortages of material, human and financial resources, TPS had no other option but to choose the waste reduction policy to cut down the costs at the shop floor. Even in the hard economic crisis, Toyota sustained and was successful because of its higher efficiency in operation and improved production system. In the meantime, inadequacy of the resources which was at first an obstacle to the company transformed into an opportunity to establish Toyota as a world class car manufacturer. ‘Lean’ approach was slowly applied in many manufacturing and management floors over the last few decades.

Lean manufacturing a systematic approach to doing more with less. In other words, Lean, is a method of increasing the amount of a manufacturer’s output, while reducing the amount of resources put in. Lean is of great interest to manufacturers around the world. Companies of all sizes employ lean principles to employ large improvements to quality, marketability and customer service.

Lean manufacturing originated long before Toyota and Ford, however the thought that it originated with Toyota is flattering since they are the ones who perfected it. By creating the Toyota Production System (TPS), Toyota found a better way to produce large quantities of product efficiently with eliminating the waste factor and while cutting down cost. Taiichi Ohno a former Toyota vice president promoted the idea of JIT (Just-in-Time) which means “producing the necessary units in the necessary quantities at the necessary time.” (Monden) Which leads to Toyota’s ultimate goal in the TPS is to improve productivity for better return in investment. To have continuous flow in a production system Toyota sought out to achieve the concept of JIT and autonomation . Since the TPS is what creates the parts who monitors the JIT system? The kanban system which is an informational system that controls quantities being produce in each process. As the discussion carries on throughout this paper about Toyota and their use of the kanban system the topic

Although the principles of lean can be dated back to the early 1900’s with Henry Ford’s development of the assembly line production, it was Kiichiro Toyoda, researching Ford’s innovation, adapted the process and further streamlining it in Toyota’s automobile manufacturing company that came up with what is now known today as the Toyota Production System. A disciplined, process-focused

The purpose of supply chain management is to manage the flow of goods and services from the procurement of raw material to the point of consumption. Furthermore, it deals with the storing of material, production, and distribution of a product that will maximize customer value and give a company a competitive advantage of the competition. Applying lean gives a company the ability to focus on constraints in the system that inhibit efficient product flow, eliminate waste and improve productivity and quality. For this to be successful its imperative companies seek to include suppliers, distributors and logistics into the process because lean requires integration, coordination and collaboration across the organization and throughout the supply chain (Agus & Hajinoor, 2012). As a result of increased transparency, companies will be more focused on performance and this will create a collective effort to reduce cost by eliminating waste and increasing productivity. Beyond the efforts to eliminate waste lean looks to incorporate customer value from the customers perspective. Simply, everything that is being done that ensures customer satisfaction is a value added step and any activity that fails to achieve customer satisfaction, which is something their willing to pay for, is a non-value added step and should be eliminated from the process. By simply knowing the process and eliminating

Lean manufacturing is a method of reducing waste (muda) in the manufacturing system. It also considers the waste due to overload and waste dude to over burden. Lean manufacturing also best known as Toyota production system or kaizen production system. Although the Toyota production system was introduced more than a century ago it has continue to develop over time. It was practiced by the Henry Ford for the manufacturing of Ford model T which was very successful between the years 1908 to 1920 which almost sold 2 Million cars a year. Later on it was developed by the Toyota in Japan. The main idea behind the lean manufacturing is to value the customer needs by reducing the waste and achieving good products with more value by consuming less resources. Muda is defined as the material or the activity for which the customer is not willing to pay. The main task of lean manufacturing is to identify Muda and to get rid of it. These products are created by using less human effort, less space, less capital, less time to produce high quality.

The primary use of lean principles was in the manufacturing domain earlier, later it spread to various processes across various industries. It was believe that the idea of lean originated in japan (Toyota), but there is evidence that the Mr. Henry Ford, the founder of Ford Motor Company has been using the principles of lean in the early 1920’s.