Achieving Excellence in Lean Manufacturing

ACHIEVING EXCELLENCE IN LEAN MANUFACTURING

PRIYA GOEL

Retention Specialist

Graduate Department, Mihaylo College of Business and Economics

Mihaylo College of Business and Economics

California State University, Fullerton - SGMH-4210
     Fullerton, CA 92834, Ph. (657) 278-7943

ACHIEVING EXCELLENCE IN LEAN MANUFACTURING

Abstract

Purpose

Lean manufacturing is successfully applied by many firms across the globe. This paper defines main objectives which are customer satisfaction and profitability of lean system.

Basic Elements

This paper discusses the main idea behind the whole lean manufacturing process. It talks about different categories as TIMWOOD in detail and important features.

Techniques

The methodology of waste elimination is explained.

Excellence achieved using lean

Benefits observed in the fields of Operation, Administration, and Strategic Improvements are described in detail in the paper.

Conclusion

Paper talks about how the theory of lean manufacturing is useful in the real industry world and where else the lean system can be implemented.

Recommendations

The final section talks about suggestions made to various industries on ways or methods that can help businesses/industries/companies achieve this excellence for the foreseeable future.

INTRODUCTION

Lean Manufacturing has been the buzz word in the manufacturing industry for some time now. The idea developed in Japan after second world war when the Japanese figured out that they did not have huge investments necessary to build industries similar to those in US.

It is a systematic approach which aims to perform more and do better with fewer workers, less inventory, and less space. This term was given by James Womack and Daniel Jones to describe Toyota Production system. This approach  is used to eliminate any kind of waste or muda. Russell and Taylor (1999) defined waste as anything other than the minimum amount of equipment, effort, materials, parts, space, and time that are essential to add value to the product. All manufacturing activities generate waste in some form or the other. The goal of lean system is, “to get right things to the right place at the right time, the first time, while minimizing waste and being open to change.” The principles of lean production enables company to deliver on demand, minimize inventory, maximize the use of multi-skilled employees, flatten the management structure, and focus resources where they were needed.

PURPOSE

Main objective of any organization is to enhance customer satisfaction and increase profitability.

Enhancing Customer Satisfaction

Customer satisfaction is primarily based on three attributes QCD (Quality, Cost, and Delivery)

Quality: Lean provides systems such Poka Yoke and Kaizen; these systems are designed and followed to ensure top notch product and service quality  

Delivery: Systems such as just in time use Kanban system to ensure that customer get delivery optimized to their requirements