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Lean Manufacturing
Tags :
lean six sigma, lean production, lean manufacturing, production engineer, industrial engineering, manufacturer,lean strategy,
Industry :
Products/Heavy Machinery
Functional Area : Product Development |
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About "Lean Manufacturing" topic:
Lean Manufacturing can be thought of as a systematic approach to reducing waste in the production process. In this sense, waste is anything (activities, processes, tools, materials, personnel) that does not add value to the product or service as viewed by the customer. Lean manufacturing strategies can save millions of dollars and produce excellent results. Here brainstorm on how lean manufacturing has inspired many new ways to eliminate waste.
1 trends
, 9 insight
, 9 debates
, 5 idea contests
, 6 question
on topic: "Lean Manufacturing"
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Six Sigma
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4
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13
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Lean Manufacturing
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Ganesh
| Argues in support of
"Lean Manufacturing"
| 9 months ago
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Thats right, I just completed my Lean Six Sigma program from AU uni
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Hardik Bhavsar
| Argues in support of
"Six Sigma"
| 3 years ago
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Six Sigma is very powerful and structured tool and very much useful in assembly line production or engineering companies, it is a mignifying glass for your process. But it may not be as much useful for FMCG manufacturing where good result can be...
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Isha Verma
| Argues in support of
"Lean Manufacturing"
| 3 years ago
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Anil Hardik.. I believe Lean is more preferable in manufacturing domain if you are in a mature industry, a service business, or an organization that handles few transactions, then perhaps Lean would work better. During this tough times typically...
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Debate: "Six sigma vs Lean manufacturing. What's hotter ?" deleted from your view.
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Yes
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5
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0
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No
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Suresh Manheri
| Argues in support of
"Yes"
| 3 years ago
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Yes, it helps a lot. Because it allows your Reach Truck Operators to fill all the empty locations with new stocks that allows the Pickers to pick the product once the order is in their RF.
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Ajit Khan
| Argues in support of
"Yes"
| 3 years ago
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Mr.Suresh i completely agree with you.Lean manufacturing emphasizes quickly eliminating obvious sources of waste by focusing on processes. Let me give an example, Starting in the 1980’s companies like Boeing began the lean process to improve the...
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Debate: "Lean Replenishment" deleted from your view.
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Lean six sigma if used effectively can help you get huge and consistent savings.
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Sustaining changes
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Prakash Saitwal
| Supported idea
"Sustaining changes"
| 3 years ago
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ix Sigma alongwith Lean Manufacturing will definitely bring sustainable changes in processes, product quality and work environment, whic will have positive effect on company performance. It should be kept in mind that, Lean Six Sigma by itself is...
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Mayank Gandhi
| Added idea
"Six Sigma Always Talked About Lean Though Not Focused"
| 3 years ago
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In all Six Sigma projects in the define phase after process mapping we look for Value Added and Non Value Added activities. And in a typical project in operations we make an attempt to remove the non-value added activites. And Six Sigma has...
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Mathew Thoams Basenth
| Supported idea
"Lean six sigma if used effectively can help you get huge and consistent savings."
| 3 years ago
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Hello Sir, I totaly agree with your attempt to justyfy the powere of lean six sigma but fundamentally i beg to differ on the way you have described both, to me Lean is a methodology which can be used to eliminate waste in the systme and reduce...
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Ideate: "How Companies can benefit by Implementing Lean Six Sigma ?" deleted from your view.
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1
Improper implementation
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Training
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Subikash Roy
| Added idea
"Lean cannot start without understanding Takt time and how to use it"
| 2 years ago
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We are trying to implement Lean Manufacturing in isolation. Lean manufacturing starts from the customer's demand which sets the Takt time. Once you start to set your pace working to the Takt time, problems surface. However, Top Management is not...
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Mark W Livingston
| Supported idea
"Training"
| 2 years ago
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Mr. Raghavendra: Excellent post, as are most of the others. What caught my attention was the refrence to ISO. Lean, as you suggest, is a journey that includes many milestones, of which will be 5S and others. The challenge to integreate Lean...
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k.nanda kumar
| Supported idea
"Improper implementation"
| 3 years ago
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People wanted to implement lean manufacturing without having the purpose of implementation. They some time fix goals which maynot be relavant. Which inturn misguide the consultant as well as the company which atlast make the system to fail.
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Ideate: "Why Lean Manufacturing Fails ?" deleted from your view.
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Increase budgets and focus on applying Lean methods
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10
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10
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Decrease budgets and focus on applying Lean methods
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prashant t deokar
| Argues in support of
"Decrease budgets and focus on applying Lean methods"
| 2 years ago
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Lean Methods are nothing but optimised process keeping in mind following paramenters 1) Cost 2) Quality 3) Delivery Here for example for production best lean process would have been single piece flow. hence infact we are saving money by reducing...
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Tapan Kumar Chattopadhyay
| Argues in support of
"Increase budgets and focus on applying Lean methods"
| 2 years ago
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We need to understand one thing and that is we need to add value for what customer pays.The customer does not pay for inventory,does not pay for waiting time, does not pay for wastages generated etc etc. Therefore, it is necessary to ensure that...
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Steven Bonacorsi
| Argues in support of
"Increase budgets and focus on applying Lean methods"
| 3 years ago
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Executive leadership should increase budgets and focus on applying Lean methods during an economic downturn to: 1. Eliminate or minimize inventory costs 2. Eliminate or minimize waiting and maximize value creation 3. Consolidate to eliminate or...
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Debate: "Lean during an economic downturn" deleted from your view.
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Japanese manufacturers re-building after the World War 2 had a difficult time. for one, they had a limited amount of people, a limited amount of raw material and money. These problems, born out of necessity led to the development of lean manufacturing practices, which they called on just in time manufacturing. Japanese manufacturing leaders like the Toyota Motor Company's Eiji Toyoda, Taiichi Ohno, and Shingeo Shingo developed a smart disciplined and process focused production system now known as the Toyota Production System, or lean production. Which incorporated The Ford production, Statistical Process Control and other techniques into a system that minimized the expenditure of resources ...
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Abhijeet Kadian
| Commented
| 3 years ago
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Hi Rajesh, Did you know that in 1574, King Henry III of France watches the Venice Arsenal build complete galley ships in less than an hour using continuous flow processes,, This shows that concept of lean manufacturing did exist in 1500 also...
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Insight: "History Of Lean Manufacturing" deleted from your view.
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Pros
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13
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4
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Cons
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David Lau
| Argues in support of
"Pros"
| 2 years ago
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Making continuous small improvements is basic idea of Kaizen; and lean manufacturing was originally invented in the manufacturing floor to eliminate wasteful processes. Then it was expanded upward to the supply chain and downward to the packaging...
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Eric
| Argues in support of
"Cons"
| 3 years ago
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This leads to sometimes huge vacancy of workers with no apologizes or reasons. In Europe, this is a real big trouble. I red a social explanation interesting enough. Generally, lean manufacturing is associated with the idea that the worker is...
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Prakash Saitwal
| Argues in support of
"Pros"
| 3 years ago
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Lean manufacturing is a careful and continuous analysis of usefulness of cost towards materials, utilities manpower to identify non-value adding factors and eliminate them. The success rate of Lean manufacturing Process depends on effectiveness...
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Debate: "Lean Manufacturing : Pros & Cons" deleted from your view.
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This is a 'short' summarize of the work of GERPISSA (R D permanent study group of car's industries and workers) studies I was studying a couple of years ago. I will write it in a couple of times, because it is quite long. I red some posts in this site I disagree, so this my answer to some incredible stuff I can not leave alone.^^ A False History There is a common picture for the 20th century industrial history which got stronger in the 90s. To be short: ''Industrial production grew up in three steps''. An almost handcraft step , with numerous products made by specialized workers, working in self organized jobs groups. They were providing a high social class, who was the only one who can aff...
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Prakash Saitwal
| Commented
| 3 years ago
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It is very good......syatematic narration of strategies for growth & staying competitive
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Isha Verma
| Commented
| 3 years ago
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indeed nice post Eric, and very insightful on the the lean manufacturing and the different growth forms...
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Insight: "Production models" deleted from your view.
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The seven wastes are categories of unproductive manufacturing practices identified by Taiichi Ohno, the father of the Toyota Production System (TPS). The categories are an integral part of the TPS (known as lean production in North America). Following are the seven wastes, as categorized by Taiichi Ohno: Overproduction -- Manufacture of products in advance or in excess of demand wastes money, time and space. Waiting -- Processes are ineffective and time is wasted when one process waits to begin while another finishes. Instead, the flow of operations should be smooth and continuous. According to some estimates, as much as 99 percent of a product's time in manufacture is actually spent waitin...
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Alexander Lewis
| Commented
| 3 years ago
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I would simply translate this as follows. Any set of manufacturing, ordering, storage, transportion - logistic - distribution operations contributing to release of cash into your system (now cash is always measurable), without compromising on...
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Insight: "Seven Categories of Wastes in Unproductive Manufacturing Practices" deleted from your view.
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Sort: Sorting leads to organization because the sort process requires people to remove any item that is not needed for production. This is a difficult task for most people because they are afraid to get rid of things and data. Items need to be red-tagged and then evaluated in terms of the value to the operations. It is best to work on one area at a time. Set in order: Again, this is organizational; it organizes each work area for maximum efficiency. To set in order means to arrange all the needed items so they are easy to use. They are also labeled so that anyone in the shop can find, use, and put them away. Setting in order eliminates a great deal of wasted time and energy. Shine: This ref...
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Ramesh babu
| Commented
| 2 years ago
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Why is Lean so Popular? It is a commonsense approach to eliminate waste. No Big Investments, No fancy jargons, applicable to any business, be it product or service. Additional Budgets should be a no/no for implementation of Lean. All you need is...
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Insight: "The 5S to create Lean Manufacturing Unit" deleted from your view.
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