Making The Lean Manufacturing Process Effective
The lean manufacturing process is an ongoing development, with no possible ending. For this reason it is not so easy to “define”, even more difficult to feel as if you have arrived. Because it is a program in development, you are always striving for improvement.
Once you have [made a commitment] to begin your official journey, you must consider if you are able to follow through with such an ongoing process process by using your in-house personnel, or if you should hire one of the many lean manufacturing consultants.
A good way to start is by asking people in your industry and size of company. You can learn a great deal from the experience of others. Word of mouth recommendations are always the best as well.
What are some lean manufacturing methods?
- Identify major areas of waste
- High defect rate
- Exessive inventory
- Waiting
- Motion
- Wasted transport
- Excess production
Several methods you will implement :
5S implementation is one of the most important things you can do for your business, without a doubt. Your clutter will vanish, you will know where every single thing is in your shop will have a place and be in its place], and everybody will be happier and more productive and more productive]. This is a good thing! The best way to start is with 5S implementation.
Kaizen and continuous improvement are one in the same thing, the word kaizen is Japanese and it has several subtly different meanings, but continuous improvement is best for our purposes.
The Kaizen event, or Kaizen blitz, is one of the more popular programs. This has become a very useful and common tool in lean manufacturing. Many companies have incorporated it into their business culture very successfully.
Value stream mapping is great program that enables you to see the big picture of where you and where you want to be. It might appear complicated at first, it is actually rather simple, once you break it down into bite-sized chunks.
An overview of six sigma reveals a methodology for quality improvement. The trademark is owned by Motorola, and as such Six Sigma is a “brand name.” Because it is also used by countless consultants who use the name of six sigma, you see it capitalized when it is used by Motorola and in lower-case letters otherwise when Motorola uses the name.
Using the lean manufacturing techniques to eliminate waste
- Quality-eliminating mistakes
- Pull systems-flow control
- One piece flow-intelligent automation
- Lead time reduction
- Level loading-mixed model production
- More effective time management
Common sense prevails
Ask a manufacturer who has successfully implemented the lean manufacturing process, you will find that they truly like it because it is just common sense. The big difference is that it is monitored and sustained company wide, or at least within a work area or department.
Once a system is in place, it is rather like another spoke on a wheel, making it stronger and better. You must use an integrated method if you want to achieve the maximum results.Just as the wheel needs all the spokes, so does a lean manufacturing program need every part of the plan in order to work properly
About us?
Jon Arnett and Randy Hough have been involved in lean manufacturing for manufacturing for over 30 years. Their main focus has been in plastic injection molding and mold making. They have an excellent website designed to give you an understanding of the lean manufacturing process and how to implement your lean program.
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