The Effect Of Lean Production On A Process Plant Essay

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.

“Lean is a systematic approach to identifying and eliminating waste (non-value-added activities) through continuous improvement by flowing the **product at the pull of the customer in pursuit of perfection.” Lockwood [24].

Chase et al. (2006) state that “lean production is an integrated set of activities designed to achieve high-volume production using minimal inventories of raw materials, work-in-process, and finished goods” (p. 471). The essential components of lean production are surplus elimination, constant work-flow, and consumer appeal. The minute these components are in the neighborhood of supply, quality and cost, this outlines the groundwork for a lean production organization. A Japanese plan of continuous progress named the Kaizen is responsible for the lean production idea. Riordan can adjust the lean production concept by employee empowerment and advancement, staying focused on making processes stronger, impact of consumer relations, rapid merchandise growth and production, and cooperation with suppliers are the imperative strategies of Riordan managing lean. Features of a lean enterprise include a combined single piece continuous workflow and near incorporation of the entire value series from raw material to finished product. In addition, demand drives production rather than predictions. This means that manufacture designing is by consumer demand or appeal and not to become system loading or strict work flows on the company floor. This will help Riordan keep minimal inventories at each step of the production process. It is also important to know that having a working participation by employees involved in

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

At last, lean production has been adopted by widely in various industries and economic sectors to implement the production system that focus on eliminating

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 Manufacturing system pursues optimum streamlining throughout the entire system by the elimination of waste (non-value added/ waste) and aims to build quality into the process while recognizing the importance of cost reduction.

The purpose of the lean production model is to eliminate the waste created during the manufacturing process and to increase the quality of the products (Continental Design and Engineering, 2008). This is done by streamlining the process and eventually reduces costs and production times. There are seven different types of waste identified by lean production: over production, inventory, conveyance, correction, motion, processing and waiting (Continental Design and Engineering, 2008).

This essay is going to analyze a case study based on lean thinking principles and techniques. It is could divide in four significant parts. First, to outline the definitions of Lean manufacturing philosophy and applied the strategies to achieving, next create future state Value Stream Map, Furthermore justification Lean Six Sigma tools and techniques, which would appropriate, and critically discussed the key successful should his idea to the Evenort Company.

Lean manufacturing is a continuous improvement practice that focuses on waste reduction. Waste in its simplest form is anything that is excessive and consumes resources. It can also be referred to as non-value-added activities that do not add value to the end product (Rizzo, 2008, 58). Sustainability on the other hand recognizes a print company’s capability to satisfy the 3 dimensions: people, profit and environment (Wirtenberg, 2013). These three dimensions are referred to as the triple bottom line (TBL). Even when a business is making a profit, anything that does not create value for customers, fulfill employees’ needs, and benefit the environment is wasteful and must be restructured to eliminate non-value-added activities (Wandiga, 2013).This is the philosophy of lean manufacturing; a beneficial concept that can help reduce the amount of wasted resources in a company and contribute to its sustainability.

There is a basic assumption that Lean Production and associated continuous enhancement companies do not provide themselves to very easy application in sectors that have large batch processes, like the food and also refreshment industries. Normally these business kinds sell their items from huge distribution or item mixing centers, as well as are not make to order businesses. They produce to a forecast, and usually the forecast preparation to production is long, causing huge distinctions in between the projection that drives manufacturing degrees, and also real need.

When the entire analysis process was completed, it was possible to identify how Toyota, having created the Lean Production method, had higher standards to any competitor in the industry. In this way, it began to replicate this method in many production plants in US and Europe. However, not only the comparative analysis of the production processes was made, but also extended to the supply chain. Once again, the results were surprising since the performance of Toyota in terms of the supply chain was much more efficient than other companies. In this way, they began to adopt similar measures to those of Toyota´s practices in order to maximize resources and making the transition from a mass production model to a Lean Production model (Graves A. and Madigan, D., 2012).

One of the major strategies implemented by Toyota and Honda to achieve greater efficiency in car production is pursuing the continuous improvement and using “lean” production system in order to eliminate waste in the organization. Toyota and Honda show a strong emphasis on total product quality not only at the expense of lead time but also in the development of productivity. Lean production system has combined the flexibility and quality of craftsmanship with the low costs of mass production (Hindle, 2008). It aims at eliminating the waste in the different stages throughout