WHAT IS LEAN?In this globalisation where company has issue to produce profitability and catering to changing need of customer become challenges. Lean manufacturing gives you the flexibility to manufacture the products according to the needs and demand of the customer. Customer is not willing to pay more prices on the contrary
Lean manufacturing or lean production, is a systematic method of elimination of waste within a manufacturing system. Lean also takes into account which created through overburden and was created true unevenness workload. Lean management is a concept related to manufacturing sector it is applicable to Other industries as well Such as retail, Service Sector.
Advantages of Lean Manufacturing, improve quality increase efficiency by eliminating waste and reducing cost. These all positive impacts improve the performance of the organisation some of the benefits observed during implications of as below
Reduced cost reduced – Cost by reducing cycle time, increase productivity ,reducing machine downtime, increase output from existing facility and eliminating the bottlenecks
Reduce lead time – Lean manufacturing help to reduced lead time, reduced with effect of reduce cycle time and also reduce work in progress inventory.
Waste reduction -all form of waste like , defect, Over productions , waiting for information, non value added activities, Transportation, inventory, motion and unutilised talent, are the waste that can be reduced by reducing Lean Manufacturing.
Improved productivity – improve productivity by improving labour productivity by reducing ideal time and ensuring that labor are not doing unnecessary task or motions
Reducing work in progress – reduction in WI, production state is known as inventory (WIP) at all state of production
Reduce defects – By quality improvement elimination of various errors and unnecessary physical waste including excess use of raw material inputs prevent defects and costs associated with repairing
Reducing waiting Time – time between process stage as well as process preparation time.
Improve flexibility by reducing change over time – Minimum changeover cost Time (SMED) improve the flexibility to produce more range of products
Better utilization of space and equipment – by eliminating bottlenecks and maximizing the rate of production with existing equipment with minimizing machine down time
Benefits of Lean Manufacturing
Benefits of lean Manufacturing are listed below. we have created a remarkable improvement in the company. For More information please visit our you tube channel.
Over Production – Producing Items for which there are no orders, which generates such wastes as overstaffing and storage and transportation costs because of excess inventory.
Waiting – Workers merely serving to watch an automated machine or having to stand around waiting for the next process step,tool,supply,parts,etc., or just having no work because of stock outs,lot processing delays,equipment downtime, and capacity bottlenecks.
Unnecessary transport or conveyance – Carrying work in process long distances,creating inefficient transport,or moving materials,parts,or finished goods into or out of storage or between processes.
Over processing or incorrect processing – Taking unneeded steps to process the parts. Inefficiently processing due to poor tool and product design,causing unnecessary motion and producing defects. Waste is generated when providing higher-quality products than necessary.
Excess inventory – Excess raw material, WIP, or finished goods causing longer lead time,obsolescence,damaged goods,transportation and storage costs and delay. Also, extra inventory hides problems such as production imbalances,late deliveries lean management principles from suppliers,defects,equipment downtime and long setup time.
Unnecessary moment – Any wasted motion employees have to perform during the course of their work, such as looking for, researching for, or stacking parts,tools etc. Also,walking is waste.
Defects – Production of defective parts or corrections. Repair or rework,scrap,replacement production,and inspection mean wasteful handling time,and efforts.
Unused employee creativity – Losing time,ideas,skills,improvements,and learning opportunities by not engaging or listening to your employees.