Overview and Background of Lean Manufacturing

Lean manufacturing is the production of goods using less of everything than in mass production: less human effort, less manufacturing space, less investment tools and less engineering time to develop a new product. A company becomes lean by continuously increasing its capacity to produce high-quality goods while simultaneously decreasing

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.

The company should also focus on lean manufacturing because it has certain positive points like increase of efficiency, decrease in the waste, improvement of control and also this will create the unique demand and need of the customer in terms of products. It will also offer cost savings strategy and will maximize the high amount of values ​​with high

Lean manufacturing is the production of goods using less of everything than in mass production: less human effort, less manufacturing space, less investment tools and less engineering time to develop a new product. A company becomes lean by continuously increasing its capacity to produce high-quality goods while

This paper presents a relevant contribution for practitioners and managers to deal with the implementation of lean. It shows that through the effective use of available tools to measure the lean manufacturing implementation of the company. Lean methods are available for them to identify specific problems and opportunities to improve the lean practice implementation.

Lean production is an incorporated group of activities set up to attain high volume production by using low inventories of raw materials, processing goods, and finished goods (Chase, Jacobs, & Aquilano, 2006). Using a lean production process, the China plant will be able to produce goods at a lower cost. Riordan China plant will need to eliminate any waste in the production process to achieve the highest level of efficiency.

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.

Lean production of vehicles was started in Japan by Toyota company. It has some similarities with the mass production; however, it is quite different from the craft production. One of the main similarities that the lean production shares with the mass production is that they both use the assembly line for the production of the vehicles, which was initiated by Ford. Unlike, mass production: “Ohno placed a cord above every work station and instructed worker to stop the whole assembly line immediately if a problem emerged that they couldn’t fix” (56). In the mass production, if the problem occurred, and no one paid attention to it while the production process, then the car company had to fix the errors in all the vehicles that had been produced no matter how large the quantity was. In the lean production of vehicles: “Ohno instead instituted a system of problem-solving called “the five why’s” (56). Taiichi Ohno, the founder of Toyota company, made sure that once the problem has been identified in the production process, then what kind of precautions company can take to prevent the problem, so it never occurs again, which saved a lot of time compared to mass production. One similarity that lean production has with the craft production is that the vehicles were not produced on a larger scale, rather they were diverse small vehicles, such as trucks and cars. In the mass production, changing the die cut process took months; however, in the lean production process reduced

138) The small improvements in different steps of the production process, when summed together, should lead to a higher level of efficiency and improved quality of products. Lean approach has been applied successfully in the private sector, particularly in production, but the approach is less frequently used in the public, and scant research has been done to establish whether it confers the same benefits and what effects it has on the productivity and the quality of the services delivered (Brady & Allen 2006, P 335).

Literature review The implementation of lean manufacturing like any other productivity improvement initiative is believed to harbour enormous difficulties (Denton and Hodgson,

Lean Manufacturing Systems were first introduced in Japan by the Toyota Motor Corporation. The Lean movement is a type of a system that relies on simple visual cues in order to manage production stages that are based on customer demand. The system is a is also a kind of manufacturing that put great emphasis on the minimization of resources, time included, that is utilized in various activities of manufacturing and provides techniques for uninterrupted quality improvement. Although this system has gained enormous momentum and respect over the last decades, some companies have found it difficult to use Lean Manufacturing Systems, and, as a result, the companies have ended up failing. The concept of Lean Systems is best understood when companies familiarize themselves with certain key insights that are utilized during the course of systems architecting. The article provides a synopsis of the lean and is divided into four parts that will be mainly used for the purpose of this review.

Applying the value stream mapping, the current state of production of structural concrete work stage could be mapped. The project manager could identify the production and environmental waste and discover some potential improvement opportunities hidden in this process. Future state map created by the project manager and the lean team to eliminate the waste and satisfy the customer?s requirements. This case study provides a groundbreaking experience of using value stream mapping that includes two dimensions, environment and product, into construction activities. The case demonstrated the value stream mapping is able to identify the sources of environmental and production waste, quantify them, and suggest reduction strategies.

Todd(2000) defines lean production as “initiative, whose goal is to shrink the waste in human effort, inventory, time to market, and manufacturing space to become highly responsive to customer demand while producing world class quality products in the most efficient and economical manner”. The Lean approach consists of several practices, which aim to improve efficiency, quality, and responsiveness to customers. Lean manufacturing is industrialized by Taiichi Ohno at Toyota Motor Company in the 1950’s (Motwani 2003). It was like “an innovation technique based on the minds and hands philosophy of the