Lean Overview

More about lean…

Over the past two decades, the concept of lean manufacturing production has gone through a dramatic evolution from an obscure and isolated practice to a mainstream, extensively publicized methodology that is well known throughout the manufacturing and supply chain industry.

The challenge with the concept of lean is that it can mean different things to different people. When the word lean is used, many people think that the scope of lean is confined to the production side of the business but it is not the case.

Lean, at its core, is a cultural and people-oriented initiative. Key to making the transition to a Lean organization is the fundamental change in the corporate culture that must be made. Central to this change is the need for the cultural change to be driven from the CEO level of the company. There must be commitment from the top to establish a clear vision for all employees to understand the benefits to them personally as well as to the organization as a whole.

The basic concept surrounding the lean philosophy is to be able to do more with less. This means processing fewer transactions and with fewer resources, (including people, machine, material, energy, etc.), and only those that are essential to satisfying a customer order.

Some of the objectives of Lean are:
- Reduced lead times
- Improved delivery performance
- Increased sales revenue
- Lower operating costs and Increased profits
- Improved customer satisfaction and supplier relations
- Increased inventory turns and a drastic reduction in inventory
- Better employee morale and Increased employee retention
- Improved quality
- Creation of additional working capital for new projects
- Reduced physical space requirement

Some of the Primary elements of Implementing Lean Operations are:
- Eliminating wastes (Muda)
- Following 5 s
- Implementing Visual Cues (Kanban)
- Visual Systems, Visual aids
- Fool Proofing (Poka Yoke)
- Single Minute Exchange of Dies (SMED)
- Autonomation (Jidoka) [*It is different from Automation]
- Value Stream Mapping and Management
- Standardization of work and Visual Controls
- Pull Production
- Following JIT (Just In Time)
- Motion Study
- FIFO (First in First Out)
- Kaizen Activities
- Total Productive Maintenance (TPM)
- Six Sigma and Lean Quality

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