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Lean manufacturing introduction 2 pages
Lean manufacturing introduction 2 pages
The problem with lean manufacturing
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LEAN MANUFACTURING-A CASE STUDY ANALYSIS Abstract:
Waste is defined as anything that does not add value to the end product from the customer’s perspective. The manufacturer must minimize the waste during producing the product so that the profit of the business can generate highly and the production cost can be minimized. In our case study we studied the manufacturing procedure of casting industry. The main task in this case is to implement lean methodology production so that the waste can be minimized.
Keywords: lean manufacturing, value stream mapping, current stream mapping, future stream mapping, lean tools.
1. INTRODUCTION
In 1850
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functioning from the attitude of the consumer who consumes a product or service, or any action that customer would be willing to pay money for.
The original there are seven wastes (muda) they
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5. KANBAN: It create a visual display of how the process is progressing and the progress can be tracked easily. Basically Kanban is a pull system and reduce the amount of work in process, it values smooth flow of work throughout the process
6. JUST-IN-TIME: J-I-T production means without any inventories the production should be complete smoothly the just-in-time is an pull system.
THE FUTURE STSTE MAPPING AFTER USING THE ABOVE LEAN TOOLS IS:
4. COMPARISON BETWEEN CURRENT STATE MAPPING AND FUTURE STATE MAPPING: Column chart 1
The number of working days decreases from 7 to 1 in future state map.
Column chart 2
The Non-value activities in current state map is huge 8858.4 minutes Compared to future state map 254 minutes.
5. CONCLUSION Future state mapping is an theoretical approach, built up by using suggested methods and if the organization utilizes the lean manufacturing tools really it increases the productivity and beneficial to organization the main theme of the lean manufacturing is “get more with less” the exact thing is observed in this case study more productivity with less
In today’s marketplace and world of business it is critical that customers receive a quality product in a timely manner from the supplier. It is also critical as a supplier and business that waste is reduce in all categories including inventory, time, facility space, storage, and also transportation. Several methods have been created and adopted over the past 20 years from top companies with successful track records such as Toyota, GE, and Motorola. One method or process that has proving to be successful is none other than Lean Six Sigma. Lean Six Sigma evolved as a concept in the early years of the 2000s which combines the Lean manufacturing method and also the concept of Six Sigma. When you blend both processes together, you have in return a better delivery schedule, better quality, outstanding employees, satisfied customers and last but not least profit. Profitability as we all know is the goal for any business, organization, or manufacturing company as well as to increase throughput while reducing inventory and operational expense (Eliyahu M. Goldratt).
In conclusion, “a study of the average benefits among US manufacturers over a five-year time frame revealed 90% reduction in cycle time, 70% reduction in inventory, 50% reduction in labor costs, and 80% reduction in space requirements” (Russell & Taylor, 2011, p. 740). There are many benefits to embracing Lean, and interest is
Lean manufacturing refers to systematic identification and elimination of waste through CI processes in pursuit of perfection (Khan et al. 2013; Yang & Yang 2013). Lean production is now used worldwide in manufacturing plants to eliminate waste from all ar...
Based on future supplier contracts, shortening lead time for delivery of parts and materials establishing leaner processes, namely addressing wastes identified through implementing a Just-In-Time (JIT) system. A centralized wharehouse system, co-located near the manufacturing plant will reduce shipping and transportation costs or look for larger space with warehousing capacity. Savings, significant enough will be a factor if space with warehousing falls within the
Lean production was developed by Toyota Led by Engineer “Ohno”. To get perfection in design criteria, lean construction took the Ohno’s production system. “The term “Lean” was coined by the research team working on international auto production to reflect both the waste reduction nature of the Toyota production system and to contrast it with craft and mass forms of production” (Womack et al. 1991).
Although it was not always easy for Toyota, they have established themselves as one of the major automobile manufactures in the world. Since Toyota’s sales have steadily increased over the years; they recently have begun focusing on the quality of the car they were producing. Unfortunately when they began the process multiple issues within the product and assembly arose bringing a negative impact to the manufacture. Toyota began to develop what we call the Lean philosophy, “form of religion”. Lean methodology is a process to increase productivity of workers, assembly lines, inventory, and management among many others, all the while keeping a close eye on the production. When they first opened their factories within the United States they pushed
In order to develop the efficiency and reduction of waste, the lean construction has been introduced as a new management principle for better functioning. There are many challenges to implement the lean concept in construction industry. In India, the execution of lean management in construction industry is a major task. Due to lack of awareness and illiterate towards the lean management principle. The main focus of this study is to utilize lean thinking concept in order to manage, improve &develop the product faster while improving or at least maintain the level of performance &quality in construction industry. In order to find out the wastages prepare the questionnaire and finding out the major factors for waste generation and less
Industries plays a vital role in Indian economy, it has emerged as a very important tool in providing relatively larger employment after agriculture. Global markets are continuously changing and demanding product of high quality with marginal cost. Such products can be produced using lean manufacturing, a philosophy that aimed to reduce wastes of manufacturing at all levels, so as to reduce product cost. Lean is about generating more values for buyers by eliminating activities that are regarded waste. Any activity or process that consume resources, time or adds cost without creating any value becomes the target for elimination. Lean Manufacturing is an efficient way to identify and eliminate waste through continual improvement. Lean is all about doing things in
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The waste management of a manufacturing company is one of the environmental matters that is mostly concerned by the society. The costs to manage the wastes from production could be very costly to a manufacturing company. Nevertheless, by using ABC system, a company can manage the production wastes in an effective and efficient manner. ABC system provides a road map to the cost reductions on waste management (Joseph & Thomas, 1995). It provides the activity-based information for the management to make better business decisions around sustainability and profit. An example would be Safety-Kleen corporation, a waste-recycling company who wanted to find an alternative to removing and recycle the hazardous wastes at a cost efficient way. It introduced ABC system into its organisation and successfully save costs in its waste management operation. The activity of transfer wastes from the collection points to the vehicles and to the disposal sites can be traced by the ABC system (Joseph & Thomas, 1995). In this way, ABC system helps to facilitate the cost measurement and provides management with accurate cost information of each activity involved in the process to make optimal decisions. Hence, with the utilisation of ABC system, it would help an organisation to have better cost control and management to support its sustainability interests on environmental
Defined as the consumer recognizes a problem or need. In this case, Porsche customer are portrayed by their desire and affection for challenges but at the same time they are facing a financial advantage that they couldn’t enjoy the most. They tried to look for the differences in their aim included the car they purchase and drive every day. In the end, they make Porsche to be their ideal purchase.
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- inform themselves on specifications, requirements, capabilities of product or service - part of consumer’s responsibility
their products/services. They are given a product/service and are required to use their best creative effort to make this product desirable to the intended audience (Krugman 37).
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