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9 lean manufacturing principles
9 lean manufacturing principles
The problem with lean manufacturing
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In today’s ever changing market place, reaching a high level of customer satisfaction is shown more and more difficult; for service industries it has shown to be even more challenging to achieve low costs and greater efficiency. Throughout the academic literature I will broadly introduce the key principles of lean manufacturing, and its processes, using USA Vacuum as a quick example to illustrate how lean processes significantly reduced their costs and maximised their efficiency. Moreover, the paper will discuss some of the problems faced when installing an operational change, followed by suggested measures with backed literature. To address the question it was necessary to select companies that have been influenced by lean, and have applied some of its processes into their service operations. Firstly, looking at an American fast-food restaurant Taco Bell, and secondly, A Canadian Hospital’s Emergency Department. Both companies note to having a lack of efficiency in their operations. Furthermore, we will be looking at how lean manufacturing truly influenced the service industries in terms of its processes, and moreover, its outcomes. Lastly, the paper will conclude the implications of lean manufacturing, and that it relies heavily on the input of involvement from everyone.
Lean manufacturing is commonly believed to have started in Japan, its key principles are to reduce all waste by eliminating such activities that do not add any value, maintaining this principle throughout the supply chain, creating multiple flows of products, by producing to demand rather than supply, and by emphasising quality (Lee and Olson et al., 2008, pp. 973--987). Toyota became the largest car manufacturer in the world in great part helped by the appli...
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Lee, S. M., Olson, D. L., Lee, S., Hwang, T. and Shin, M. S. 2008. Entrepreneurial applications of the lean approach to service industries. The Service Industries Journal, 28 (7), pp. 973--987.
Ng, D., Vail, G., Thomas, S., Schmidt, N. and Others. 2010. Applying the Lean principles of the Toyota Production System to reduce wait times in the emergency department. Cjem, 12 (1), pp. 50--57.
Radnor, Z. and Osborne, S. P. 2013. Lean: a failed theory for public services?. Public Management Review, 15 (2), pp. 265--287.
Shah, R. and Ward, P. T. 2003. Lean manufacturing: context, practice bundles, and performance. Journal of Operations Management, 21 (2), pp. 129--149.
Suarez-Barraza, M. F., Smith, T. and Dahlgaard-Park, S. M. 2012. Lean Service: A literature analysis and classification. Total Quality Management & Business Excellence, 23 (3-4), pp. 359--380.
There are many people that benefit from Lean Six Sigma which include mainly customers, suppliers, employees, and also stockholders. Lean Six Sigma is a way for businesses to improve, to reduce waste and to become more successful. In the future, more and more organizations will adopt or practice some of the Lean, Six Sigma, or both in order to stay competitive in today’s market. In some cases, blending both Lean and Six Sigma can be costly and difficult; however the end result can create an organization that focuses on quality, accuracy, and speed to meet the goal which is profitability.
One noticeable thing about the lean approach to work force management was the respect and trust invested in the work force as well as the system. The workers were earlier seen as negative necessities of the system rather than contributing members and understandably the workers felt that since they were going to be with the firm for a long time period, things should be done their way.
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...
Complete administration of cost is done by lean internal operational functions adopted by the Tesco. Record of accepted salespersons and organizing scheme are upgraded regularly and endlessly. Effectiveness and efficiency of such operations are maintained by these policies adopted by Tesco.
Achieving quality of conformance involved conform to specifications that involve providing customers with a quality product at the right price which accounts for the cost of materials. In order for a company to achieve and produce a successful product that customers want and need, it is vital that quality management and lean systems play front row. Quality management helps organizations to reduce waste and inventory. “Lean is about challenging the way things are done and opening our eyes to that waste and inefficiency” (Lean Benefits - Benefits of Lean, Why Lean is Important, 2015). Within each of these concepts are important tool and techniques that organizations can use to achieve a quality product. In this paper I will discuss “cost of quality” from the quality management side and “kaizen’s” from the lean system side, while discussing how each of these concepts are implemented into my own life or
For organizations who have committed to invest and deploy quality systems improvement programs, it is a huge task for every member who is a part of the transformation. The benefits are felt once completed and outweigh the cost from a long-term standpoint. Col. Larsen offers a compelling argument that Lean principles, when properly applied, also result in significant improvement and transcends industry boundaries. Leadership from all levels must challenge traditional approaches, communicate, and execute as a team to design and obtain excellence in governance of safety.
A LEAN Company is our best description and our business philosophy (creating more value for customers with less resources), which pursues to deliver what the customer wants, when they want it, at maximum value with minimum misuse.Through the application of LEAN, we achieve more fulfillment as it helps to reduce the possibility to constantly be fighting a battle against difficulties. Besides, we promote a Continuous Improvement Culture in our performance.
In the new global economy, with the improved information technology, and the increased competition, a study by Levy (2007) shows that, many companies have attempted to recognize and implement lean production (LP) systems, established by Toyota, that involve goals such as just-in-time (JIT) delivery, low inventories, zero defects, flexible production in small batches and close practical cooperation with suppliers. Therefore, this paper will present how Kellogg’s has been able to manage its lean production in a very efficient way to create long term value products and competitive advantage.
Outsourcing labor and materials in a global market can significantly stretch the supply chain structure. This can have both positive and negative effects. Looking to different countries provides the opportunity to access different markets and find the lowest possible manufacturing costs. Many companies also embraced the Toyota Motor Corp. model of just-in-time inventory and other lean manufacturing techniques that emphasized speed and cost reduction (Bosman, 2006...
TQM is a system of continuous improvement of work processes to enhance the organization’s ability to deliver high-quality products or services in a cost-effective manner [2]. The focus of TQM is to improve customer satisfaction and reduce waste [3]. Customers include ...
Kasra Ferdows is a researcher from Georgetown University in Washington, DC and Fritz Thurnheer is a consultant from the Hydro Aluminum Extrusion Group in Lausanne, Switzerland. Ferdows and Thurnheer examined the difference between factory fitness and leanness. The article examined how the Hydro Aluminum Extrusion Group designed, launched, and managed a comprehensive factory fitness program in 42 locations across five continents between 1986 and 2001. Importantly, the factory fitness program was based on the sand cone model, but was slightly modified to fit the business strategy of the Hydro Aluminum Extrusion Group. The sand cone model was used to avoid tradeoffs between the manufacturer’s production capabilities. Over a long period of time the sand cone model can be used to improve multiple production capabilities
...hould be noted that the process of Lean management was first applied in the area of manufacturing. Some analysts tell that his particular business management process came out of the Toyota Company’s production system of cars. It should be noted that the Japanese are very much inclined to adopt anything that would reduce costs and eliminate wastes. Hence, it is no wonder that the Japanese are known for their simplicity and design and the minimalist view on things. However, nowadays has evolved from the area of manufacturing and could now be applied in the area of management. Before moving forward to the essential principles of Lean management, it would be better to clearly define it first. The said book by Bradley did not really give a definite and concise definition of Lean. Instead, he tried to define this said business management concept though examples.
Pfiffner, J. P. (2004). Traditional Public Administration versus The New Public Management:Accountability versus Efficiency. Unied States: George Mason University.
Lean production is an approach to production developed in Japan. Toyota, the Japanese car manufacturer was the company that invented lean production. The whole aim of lean production is to reduce the quantity of resources used up in production. By doing this, lean production uses less of - factory space, materials, stocks, suppliers, labour, capital and time. Lean production reduces costs, increases efficiency and output and improves motivation. Lean production involves using a range of practices designed to reduce waste and improve productivity and quality.
Chase, R. and Apte, U. (2007). A history of research in service operations: What's the big idea?.Journal of Operations Management, 25(2), pp.375--386.