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Lean Manufacturing Essay

1080 words - 4 pages

ML303Moving to mastersAn individual reflective reportA personal development planName: Klara KovarikovaStudent Number: 13803236Tutors: Vicky RichardsWord Count:Hand in date: 13th December 2013Introduction to the leanThe aim of lean manufacturing is to achieve substantial competitive advantages on the market. It is an interest for all companies through around the world to become competitive. Companies at all sizes applied lean principles and do improvement in quality, productivity, customer service and profitability. Bhasin (2004) point out that lean production should be view as a philosophy not as a process. It is an overall mapping of process from the raw material to the final customer. The word "lean" is chosen to explain the strategy which enables to produce more for less. Quarteman (2007) said, there was a misconception that lean only works in big companies with repetitive and high volume activities but lean was successful in many kind of industries. Lean production examines the process as a whole. There is a need to achieve a smooth production flow and to eliminate waste.Implementation of leanTo implement the lean principles in practice, company should follow several steps:Evaluate current stateFirst of all the company has to examine all areas of process where it will be appropriate to implement lean techniques. Process mapping help us to draw it. Process mapping helps toSpotlight to wasteStreamline the work processesDefine and standardisePromote deep understandingBuild consensushttp://www.strategosinc.com/process_map_example.htmWaste means all activity that does not add any value in the process. The other term for waste is MUDA. Where the waste is found lean philosopthy should be applied. According to Slack (2013), the elimination of waste is a core lean idea. Toyota have identified 7 different types of waste in operations, both in service and production:Overproduction - producing more than consumers demandWaiting time - unnecessary waiting time between production stepsWork in progress - supply levels and work in progress inventories too highTransportation - moving materials inefficientlyOver-processing - inefficient process, poor maintenanceMotion -people and equipment move between tasks inefficientlyDefects - quality waste, time spend finding and fixing production mistakesMoreover there is a waste in workforce. In other words workers are not used efficiently or organization waste their potential.Determinate future stateWorkflowSlack, (2013) argues in his book that company has to determinate process and layout. It will help to identify what kind of machines the organisation will need. Layout means how the recourses will be transforming. It is important decision because if the layout proves wrong, it can lead to over-long or confused flow pattern, customer queues, long process times, inflexible operations, unpredictable flow and high cost. Layout must start with a full appreciation of the objective that the layout should be trying to...

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