Lean Manufacturing Outcomes Essay

Study On Lean Manufacturing And Its Outcomes Essay
Synopsis of Major Research Project
On
Be Keen To Lean: A Study on Lean Manufacturing & Its Outcomes
Submitted as partial fulfilment for the requirement of Course Curriculum for award of Master of
Business Administration Degree of Devi Ahilya Vishwavidyalaya, Indore with specialization in
Operations Management and Human Resource Management
Submitted By– Guided By– Sandeep Dounde Dr. Sumeet Khurana MBA Semester III Professor
Enrol. No. – DX1407837
Faculty of Management Studies, Acropolis Technical Campus, Indore
INTRODUCTION
The Lean Manufacturing approach is meant to transform non–value added activity into value added
activity. Lean Manufacturing technology has its impetus and focus on whole operation. Lean
Manufacturing methods are inclusive of all employees and involve a major change in the embedded
attitudes of the individuals that make up the organizations. In today 's highly competitive world, the
Indian organizations are striving hard to
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Essay Lean Manufacturing
Lean Manufacturing is a very popular and successful strategy, which many manufacturing
companies have adopted over the past 60 years. Mone Consulting Firm has been referring this
method for more than 20 years at a high success rate of 99%. If implemented effectively "going
lean" for Classic Cable Company will have a positive impact throughout the entire enterprise, by
introducing attainable goals. The goals of lean manufacturing will achieve: a balanced rapid flow,
eliminate waste and disruptions, and maintain a flexible system. After reviewing CCC's case
background, some overall recommendations and problem solving should be considered in the
following order. I've noticed that no expansion can be done and reorganizing work cells would be ...
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Customers don't like to wait, they want it now! A quick response to RFQS will satisfy the customer
which in the long–run will reduce CCC's lead time and possibly match the customers expected time.
Furthermore, customers need to stop sending quotes directly to TSS. Maybe by advertising, all
RFQs must be sent to our sales administrator for processing purposes. In Step1: Response to quote
request, a modular design should be used for new products. This would cut the time in designing,
reducing parts and abridging assembly for CCC's engineering team. As well as eliminating errors
from 40% to 0. The TSS should also be using the ERP system to check to see if materials and
shipping options are available; so that a better quote package can be determined. Step 3: Sales order
entry, it should not take the planning department within 4 hours to enter data. This step needs to be
taken as soon as possible. Mistakes are costly and having 25% in errors are not acceptable so if we
trim the timing of entering the data CCC still has wiggle room to produce the sales order package
effectively and have material arrive on time . In Step 4: Work order Entry and Release to
Stockroom, this step is perfect. It's important to keep both ERP and MRP systems up to date so
every department knows what is going on.

Advantages Of Lean Manufacturing
INTRODUCTION. Lean can be simply described system that is designed to create more value for
customers with fewer resources. Lean principle is best described as a series of processes or
methodology that eliminates waste in a production cycle. Lean principles originated from Japan in
the manufacturing industries, commonly in the Automobile sector. Over the last decade, Lean has
stepped outside the norms of manufacturing to become a process improvement method for both
service sector and more recently in public sector organizations that are interested in improving their
output efficiency and increase customer value. Wikipedia defines Lean as the set of "tools" that
helps in the identification of waste and its elimination. The waste is also referred to as Muda. It says
elimination of waste improves quality and thus reduces production time and cost.
(https://en.wikipedia.org/wiki/lean_manufacturing) The lean process is best represented in the
diagram below – Figure 1 ... Show more content on Helpwriting.net ...
Various written works have explored the Lean advantages and applications. The term Lean was
initially instituted by Krafcik (1988). Therefore, Womack, Jones, and Roos (1991) utilized the term
Lean implementing to portray the Toyota creation framework

Value Stream in Lean Manufacturing
Mapping the value stream | | |Jared Lovelle. IIE Solutions. Norcross: Feb 2001.Vol.33, Iss. 2; pg. 26,
7 pgs | Subjects: Production methods, Value added, Efficiency, Mapping Classification Codes 9190
United States, 5310 Production planning & control Locations: United States, US Author(s): Jared
Lovelle Document types: Cover Story Publication title: IIE Solutions. Norcross: Feb 2001. Vol. 33,
Iss. 2; pg. 26, 7 pgs Source type: Periodical ISSN/ISBN: 10851259 ProQuest document ID:
68597087 Text Word Count 3398 Document URL: http://proquest.umi.com/pqdweb?
did=68597087&sid=3&Fmt=4&clientId=10342&RQT=309&VName=PQD |Abstract (Document
Summary) ... Show more content on Helpwriting.net ...
Although an IE, | | | |this gentlemen was caught | | | |in the same quagmire that | | | |many of our
accounting and| | | |management co–workers are | | | |in – batch and queue | | | |mentality. This article |
| | |outlines a tool – | | | |value–stream mapping (VSM)|

Lean Production Of Lean Manufacturing
2.3.1) Lean Manufacturing Review Lean originally comes from the thought of scarce resources. The
Japanese automotive manufacturer called Toyota was the one who introduced this method with
innovations such as JIT, and so forth [14; 44; 28]. Lean operations were used as a different method
for capital–intensive mass manufacture in order to help firm use resources more effectively and
efficiently. As a result, the firm will be able to reduce muda activity and non–value adding tasks.
The procedure of lean implementation and research had been widely used by many organizations
across the world. Conglomerates found out that the manufacturing process need not only
improvement in performance, but also the development must be extended and ... Show more content
on Helpwriting.net ...
The main role of "lean" supply is to strengthen the relationship and collaboration between suppliers–
customers. According to Ellram [10], the author has defined the concept of lean as the continuous
bond between the organizations which concerns to the contract and commitment in the long term
relationship and a shared advantages and risks. Additionally, there are also some other features after
the relationship and commitment between suppliers until customers. Those features are the trade of
concepts (communication), data, and advantages such as merge inR&D, long–term relationship, and
so forth [38; 40; 9]. The concept of lean supply also is being as the start of the enhancement in
system in terms of taking the proactive role in improving the usual technique for similar advantages
throughout the supply chain. As from the authors, the suppliers will work on working with
manufacturer and ongoing collaborate until customers in both direct and indirect ways [13].
Occasionally, the managers will face with the situation where wastes cannot be found and
discovered all. The various tools are then introduced for finding those wastes throughout the area by
observing in products and circumstance's information. Six of the noticeable tools are stated. The first
tool is called "Process activity mapping". The very noticeable role of this tool is the function as the
identifiers of lead–time for both merchandise

The Roots Of Lean Manufacturing
Production managers are faced with many challenges within their facilities such as managing
inventories, controlling waste, and managing an ever changing production schedule. Managing
product flows can be difficult when balancing supply chain inventories with demand changes or
scheduling problems due to throughput variations. Several methods for managing these challenges
have been developed through the years and each have their own advantages and disadvantages for
different applications. The methods discussed in this paper will be limited to the Theory of
Constraints, Just in Time, and Material Requirements Planning. All three methods are designed to
manage different aspects of a manufacturing facility's product flow but all three were ultimately
developed as an optimization strategy for the manufacturing process. The roots of Lean
Manufacturing is one of the earliest management strategies to be developed to address the
challenges for production control and may well have been the birth of strategic production control as
we know it today.
LEAN MANUFACTURING
At the end of the 18th century Benjamin Franklin wrote about reducing waste in Poor Richard's
Almanac and this may very well have been the starting point for waste reduction thinking. At the
beginning of the 20th century Henry Ford was the first person to truly integrate a production process
with waste reduction, inventory control, and time management in mind. This paved the way for
Lean Manufacturing strategies to

Lean Manufacturing And The Production System
Definition
Lean manufacturing is the process of eliminating waste in every area such as production, supply
chain, maintenance, quality control and factory management.
The ultimate goal of lean manufacturing is to decrease the human effort, inventory and time to meet
the customer demand in the most efficient and possible economical manner.
Lean manufacturing is referred to the methods of manufacturing that gives maximum value and
minimum waste in the process that is followed. Lean manufacturing is also used to focus on the
resources to maximize the value added features and eliminate the non–value added features.
There were different names for Lean over the years which was primarily developed from the Toyota
Production System (TPS) it has ... Show more content on Helpwriting.net ...
In Ohno's book 'TPS – beyond large scale production' Ohno described how TPS evolved out of
need, as the market place in post war Japan required small quantities of cars to be produced in many
varieties. This became very different ot the Ford principle of mass–production.
Although TPS began in 1950, Japanese firms noticed only in the 1973 where oil crisis took place.
Since then the system has been studied, copied and implemented across many industries.
Womack, Jones and Roos (1990) coined the phrase "Lean Manufacturing" in the MIT five–year
study into the automotive industry that led to the book "The Machine That Changed the World".
This gives a pretty good insight into The History of Lean Manufacturing
Even with the massive amount of research that has taken place into the Toyota Production System,
fifty one years after it was born, Slack et al still refer to Lean Manufacturing as a 'radical departure
from traditional operations practice'.
The Timeline of Lean Manufacturing:
1926 – Sakichi Toyoda sells foreign rights to loom and Sakichi Toyoda patents Toyoda Automatic
Loom with Non–Stop Shuttle–change motion
1936 – Kiichiro Toyoda (Sakichi's son) starts Toyota (then called

Lean Vs. Lean Manufacturing Industry
Lean accountings primary use is in the manufacturing industry. A lean manufacturing company in
which lean accounting is used looks to attack wastes in all forms. This in turn reduces the cost of
goods sold. Lean accounting instead uses value stream costing. "Lean accounting experts believe
that accounting itself can be lean, which can contribute to profit rather than just calculating it. Cost
do not exist to be calculated. Costs exist to be reduced" (Taiichi Ohno). Lean accounting accentuates
removing waste, increasing product turnover and reducing inventory levels in the manufacturing and
production processes. The focus is on producing to meet customer demand while also achieving the
shortest production cycle. Three benefits, which ... Show more content on Helpwriting.net ...
This results in making it almost impossible to calculate standard costs, standard material usage, and
standard labor rates that show up on the financial statement. Examples of some companies that use
lean accounting are Toyota, Lantech, Intel, Caterpillar Inc., Ford Motor Company, and John Deere
just to name a few. Intel suggests that it use to take fourteen weeks to introduce a new chip but it has
since been reduced to ten days since its implementation of lean manufacturing and accounting.
Some of the techniques used by Ford Motor Company are "effective work groups, zero waste/zero
defects, aligning global capacity with global market demand, optimizing production throughout, and
using total cost to drive performance"(Ford Motors Company) Lean accounting is organized
differently than the cost accounting. Cost accounting uses departments, the product moves to the
next department for completing that phase, and then on to the next department all the while material,
labor, and factory overhead are accounted for separately in each department in order to control cost
and give assessments where waste is happening. This helps management to implement processes to
regulate losses and make changes to productivity. Unlike this traditional system, which has been
used in the early 1900 's lean accounting, uses value streams. "A value stream includes everything
that is done to create value for a customer and can be easily associated with the product or

Lean Manufacturing Case Study
Implementation of the Comprehensive Technique of Lean Manufacturing in Small Scale Process
Industries : A Case Study
Abstract: To sustain the competition and remain alive in market the enterprises must implement the
practices of Lean manufacturing techniques. The implementation of Lean producing enhances
productivity of plant at the same time reducing scrap within the processes. In small scale process
industry the major problem is of In–process inventory which increased the overall cost. In this paper
such In–process inventory problem is analyzed by Break Even Analysis Method. Finally, the
qualitative approach was used to decide most effective tool and Major potential benefits of Lean
Manufacturing Techniques.
Key words: Lean manufacturing, market, mass production, productivity, reducing scrap
INTRODUCTION
Lean method produces the little goods that are definitely will sell off and these constraints
production of more goods than necessary. LM working on the core principle 'work smarter, not
harder'. Lean production is aimed toward the elimination of waste in each space of production
together with client relations, product style, provider networks and manufacturing plant
management. Its goal is to include less human effort, less inventory, less time to develop ... Show
more content on Helpwriting.net ...
Cotton gining and handling products e.g. Belt conveyors ,distribution Trolley, Pre and post cleaners,
auto feeders ,Air separators ,Divergent and Dampers . Electrical enclosure and Distution e.g. panel
Modular enclosure 19" rack sytem Distibution board with assembly and wiring. Manufacturing of
cotton humidification system and sheet metal component . we have selected this products and
quationaire is produced to find where is lots of inventories is in process .the quaionaire is shared
with Expert and workers to go to the depth.The problem is decided to diagnosed by Lean
Manufacturing

General Motors with Lean Manufacturing
General Motors with
Lean Manufacturing
An Introduction of GM Global Manufacturing System
Operations Management Team Project
Contributed by
We Make A+ (sort by number):
유형근 – 2009 050 444 오슬기 – 2010 049 712
손무화 – 2010 054 149 주시건 – 2010 059 605
김학운 – 9125 620 120
Division of Business Administration, Hanyang Univ. ERICA
Ansan, December 2012
Contents
Part 1.Overview of General Motors 2
1.1 Why General Motors? 2
1.2 Introduction of General Motors 3
1.3 Basic Information 3
1.4 History of GM 4
1.5 GM's family 4 Part 2.Introduction of Lean Manufacturing 4
2.1 Definition 5
2.2 Lean and TPS 5
2.3 Theme: Efficiency 6 Part 3.GM's Global Manufacturing System 6
3.1 Application of Lean Manufacturing 6
3.2 ... Show more content on Helpwriting.net ...
1.3 Basic Information
Industry – Automotive
Founded – September 16, 1908
Founder(s) – William C. Durant
Headquarters – Renaissance Center, Detroit, Michigan, the US
Number of locations – 156 facilities on six continents

Area served – Worldwide
Product – Automobiles, Financial Service
1.4 History of GM 1908 | Founded by William. C. Durant | 1910–1929 | The rise of the automobile
captured imaginations and sparked invention. | 1930–1959 | GM's commitment to innovation lent
optimism during tumultuous world events. | 1960–1979 | GM offered forward–thinking answers to
an increasingly eco–conscious world. | 1980–1999 | The close of the 20th century brought
tremendous global growth for GM | 2000–2008 | Trying economic times saw GM embracing an
enduring passion for innovation. | Today | We are passionate about designing, building and selling
the world's best vehicles. This vision unites us as a team and is the hallmark of our customer–driven
culture. |
1.5 GM's family
Part 2.Introduction of Lean Manufacturing
2.1 Definition What is lean manufacturing(lean)? Lean manufacturing, lean enterprise, or lean
production, often simply, "Lean," is a production practice that considers the expenditure of resources
for any goal other than the creation of value for the end customer to be wasteful, and thus a target
for elimination. Working from the perspective of the customer who consumes

Improvement Of Manufacturing Operations Through A Lean...
Research Paper review on "Improvement of Manufacturing Operations through a Lean Management
Approach: A Case Study in the Pharmaceutical Industry"
This is a review on the research paper "Improvement of Manufacturing Operations through a Lean
Management Approach: A Case Study in the Pharmaceutical Industry" by Maria Elena Nenni, Luca
Giustiniano and Luca Pirolo submitted to University of Naples Federico and University LUISS
Guido Carli
Abstract:
At the current situation, Lean Manufacturing has turned into an overall marvel. It is entirely
effective in drawing the consideration of organizations of all sizes. An extensive number of
organizations are taking after Lean advancements and encountering unlimited upgrades in quality,
production, customer service etc. According to lean principles, any use of resources that does not
deliver consumer value is a target for change or elimination. It also refers to the elimination of non–
value adding/wastes. This Lean approach has mainly been applied in manufacturing, notably in
Toyota, and the Toyota Production System, from where Lean originates in the early 1960's but not to
a complete extent. However, lean has also been widely applied in non–manufacturing areas. 'Lean
Management', or rather 'Lean production' is considered to be a smart approach on a system of
measures and methodologies. Considering the aspects on a whole, the potential to bring the concept
of Lean in various fields of activity like product development, supply chain,

Lean Manufacturing Is Not Just A Production Method
Introduction
Lean manufacturing is not just a production method. It is a way of life. One could say that it is
simply a way of providing customers what they want, at a price they can afford, when they want it
(Leaning Forward). However, it is much more than just satisfying the customer's needs.
Lean manufacturing originated after WWII in Japan to help revitalize their manufacturing industry.
The industry was booming in the United States because of the revolutionary invention of Henry
Ford's Model T and the creation of the flow production, but the lack of variety created demand and
Toyota answered that demand (Lean).
Kiichiro Toyoda and his team at Toyota realized by modifying the system they could make the
process have less wait periods ... Show more content on Helpwriting.net ...
Pull Flow is the concept of a continuous flow of production and enables operators to identify and
pull defective products from the production line. Kaizen is the approach used by employees to
implement continuous improvements to a manufacturing process (Gembutsu).
Muda is the concept of wasting resources to create something with no value. The types of wasted
include over production time, inventory, transportation, process inefficiency, defects, and
unnecessary motion (Vorne Industries).
Jidoka is the process of identifying a defect before getting to the finished product and is
accomplished by automation. It is carried out by the automation knowing what a product defect is
and alerting an operator (Gembutsu).
Takt is the method used to align the customers demand with the production and is paced by using
Takt Time. Takt Time is the pace of production and is calculated by dividing production time by
customer demand (Gembutsu).
Procedures
The Spartan Assembly Line involved several processes. To start the assembly process the orders or
the colors of the cars were called out to the paint process. After the paint was applied to the car, the
body went to glass and then onto accessories, where the parts like the front grill were added.
While these processes were going on, two other processes were also going on. When the orders or
paint colors were called out, the chassis

The Principles Of Lean Manufacturing
The primary use of lean principles was in the manufacturing domain earlier, later it spread to various
processes across various industries. It was believe that the idea of lean originated in japan (Toyota),
but there is evidence that the Mr. Henry Ford, the founder of Ford Motor Company has been using
the principles of lean in the early 1920's.
Henry ford thought that shortening the time a product takes in a production is a key solution to
reduce the overall cost of the product [4]. If a product spends large amounts of time in a process of
manufacturing, the overall costs goes high, one of the reasons being more material handling.
There are primarily 5 principles of lean manufacturing [9]. Those 5 principles are as follows:
1) Specifying ... Show more content on Helpwriting.net ...
Most people tend to misunderstand lean by identifying the non–value added processes and working
on them to eradicate them which in turn increases the amount of non–value added tasks.
VALUE STREAMS: Value stream is a map of processes in the order of which they run. Creating a
value stream is of key importance in understanding the value added and non–value added processes.
Value streams help us identify the whole production process as a whole while giving us insight on
all the sub processes that go through. Value stream processes may also depict the flow of
information. VSM requires various departments to come together and prepare the map, it is not an
individual job.
FLOW: We continuously try to establish a flow between values added processes. A value added
process must not be hindered by a process which of no value. If possible, non–value added
processes must be done in parallel.
PULL: lean concentrates on pull system. Pull system is making the product when it is required. This
tends to minimize the wastage and also has minimal inventory. Employees stay idle when there is no
order but the value is from the final product. Industries following push system can face a few
problems in the form of over production and inventory wastages. Producing first and storing it in
warehouse eats up the capital that is invested and is a considerable waste.
PERFECTION: Perfection is achieved when the

Lean Manufacturing Is The Pursuit And Elimination Of Waste
"Lean manufacturing is the pursuit and elimination of waste that simultaneously embodies respect
for people" (Hansen and Mowen 6). Key purposes of lean manufacturing are to eliminate waste,
reduce costs, and to maximize customer value. As companies try to cut down on the amount of
waste they produce, their goal is to maximize their efficiency and cut the costs that are incurred.
Lean manufacturing is described as, "delivering the right product, in the right quantity, with the right
quality, at the exact time the customer needs it and at the lowest possible cost" (Hansen and Mowen
778). This idea seems somewhat unrealistic, but methods of implementing lean manufacturing have
proven to be successful in achieving this goal.
Lean ... Show more content on Helpwriting.net ...
The demand for products "pulls" products through the manufacturing process. The goal is to
produce a product only when it is needed and to only produce the quantity that is needed. The last
principle of lean manufacturing is pursue perfection. This principle keeps the goal of producing
highest quality products for the lowest cost in the least amount of time. Waste is eliminated when
detected and defects are prevented. Through experience implementing lean manufacturing, the
pursuit of perfection becomes achievable.
An important element of lean manufacturing is lean accounting. Lean accounting deals is an
approach to costing that supports lean manufacturing through both financial and nonfinancial
measures. Lean accounting differs from traditional accounting cost methods. "Rather than
categorizing costs by department, they organize them by value stream, which includes everything
done to create value for a customer the company can reasonably associate with a product or product
line" (Kroll). A key focus of lean accounting is productivity measurement. Productivity
measurement focuses on the inputs and outputs of manufacturing. As waste is decreased and ideally
eliminated, the overall productive efficiency of the manufacturing processes should increase.
There are many benefits companies can acquire from implementing lean manufacturing. At the same
time, those companies will also

Lean Manufacturing : An Overview
LEAN MANUFACTURING
An Overview
CONTENT Description Page No.
I. Lean Manufacturing Overview: 2
a. Introduction: 2
b. Manufacturing management: 2
c. Lean as a management approach: 3
II. Lean Manufacturing Principles: 3
III. Wastes in Lean Manufacturing: 4
IV. Performance Measurements: 5
V. Implementation of Lean: 5
VI. Barriers to implement lean: 7
The cement industry is ideal example of the continuous process manufacturing where the traditional
mass production system is adopted in order to produce, accumulate, and move thousands tons of
materials between the work areas. The nowadays challenge is to change the cement industry from
traditional mass production into more effective production system aiming to increase the
productivity, overall performance, and capacity utilization to meet high marker demand. The cement
industry is forced to reduce the production costs and delay times in order to take advantages in the
global competition environments.
I. Lean Manufacturing Overview:
Introduction:
In the twentieth century two major manufacturing revolutions have been introduced. Both
revolutions have been developed at the automobile sector. The first revolution was mass production.
In the 1900s the demand for cars has raised dramatically, and the automobile sector has become very
competitive. Craft production has dominated the automobile sector; in fact using of the craft
production was inadequate to manage the high demand at that period. In that

Lean Manufacturing
The current issue and full text archive of this journal is available at www.emeraldinsight.com/1741–
038X.htm
JMTM 17,4
Critical success factors for lean implementation within SMEs
Pius Achanga, Esam Shehab, Rajkumar Roy and Geoff Nelder
Department of Enterprise Integration, School of Industrial and Manufacturing Science, Centre for
Decision Engineering, Cranfield University, Cranfield, UK
Abstract
Purpose – The aim of this research paper is to present the critical factors that constitute a successful
implementation of lean manufacturing within manufacturing SMEs. Design/methodology/approach
– A combination of comprehensive literature review and visits to ten SMEs based in the East of the
UK were employed in the study. The ... Show more content on Helpwriting.net ...
Several authors have reiterated the importance of cost factors and their reduction strategies in the
current production process (Kulmala et al., 2001; Roy et al., 2001; Roy, 2003; Shehab and Abdalla,
2002). They assert that, cost factors are crucial, therefore, fundamental to the survivability of most
organisations. Unfortunately, the idea of applying lean manufacturing has not been adopted by
meaningful numbers of SMEs with any conviction. These companies require that the
implementation costs and the subsequent benefits of lean manufacturing adoption, be projected
upfront before they are able to commit. Therefore, this research paper aims to outline some of the
factors that are perceived to be critical in the successful application of lean manufacturing within
SMEs community. The main objectives of the research were to:
JMTM 17,4
. . .
explore the operational activities of SMEs in order to identify their cost drivers; investigate the
dimensions of lean manufacturing applications within SMEs; and outline critical factors that
determine its successful application within SMEs.
462

Literature review The implementation of lean manufacturing like any other productivity
improvement initiative is believed to harbour enormous difﬁculties (Denton and Hodgson,

Overview and Background of Lean Manufacturing
Overview and Background of Lean Manufacturing
History of Lean Manufacturing
Toyota Production System Overview
The concept of Lean Manufacturing gets is roots from car manufacturing in the early 1930s and
1940s. Stemming from innovative production techniques developed and implemented by Henry
Ford, modern day Lean Manufacturing was developed by Taiichi Ohno of Toyota Motor Company
after World War II as a result of the diverse market conditions the company faced.
At a time when western car manufactures, like Ford and General Motors, where using mass
production and economies of scale manufacturing methods, Toyota faced very different business
conditions. Toyota 's market was very small and diverse, leaving the organization to ... Show more
content on Helpwriting.net ...
Just as with Lean Manufacturing, Lean Construction focuses on establishing value, as defined by the
customer, it with the goal of constructing a product that delivers on that value. Thus, value must
come before planning and design. (Mohammed).
Principle 2: Identify and Map Value Stream
In Lean Manufacturing the value stream identifies the necessary steps for developing and creating a
product that is valuable from the customer's perspective. In other words, the value stream determines
how and when decisions are made in the production process.
Lean Construction uses a similar technique called value stream mapping, as known as process
mapping, to understand how a construction project will be designed, supplied, and built. Hence, this
is where the planning and design aspects mentioned in the above section, come into play. Typical
Lean Construction value stream maps consist of the following:
Problem solving tasks: ranging from concept through detailed design and engineering to production
launch.
Information management tasks: ranging from order taking through detailed scheduling to delivery.
Physical transformation tasks: ranging from raw materials to producing finished products that get
delivered into the hands of the customer.
As demonstrated above, these mapping techniques highlight how the construction plan, design,
logistics, and operation

Production Process And Lean Manufacturing Process
INTRODUCTION
Quality in manufacturing has become an integral part of the production process and lean
manufacturing. The objective is to ensure that all customer project requirements are met to
specification while eliminating waste. Some of the world's largest company's require suppliers to be
on their approved supplier list prior to considering doing business with your company. One of the
major requirements to get on an approved supplier list is to have a certified quality management
system in place. Manufactures recognize the importance of quality certifications and lean processes
and use them as a competitive advantage in gaining new business and retaining current customers.
WHAT IS LEAN
The core idea of lean is to relentlessly work on eliminating waste from the manufacturing process.
Waste can be defined as any activity that does not add value from the customer's perspective.
According to research conducted by the Lean Enterprise Research Centre (LERC), fully 60% of
production activities in a typical manufacturing operation are waste – they add no value at all for the
customer. Every company has an opportunity to improve, using lean manufacturing techniques and
other manufacturing best practices. Techniques that enable you to deliver higher quality products at
significantly lower costs (Vorne Industries Inc., 2010–2013).
LEAN PRINCIPLES
Lean Principles in manufacturing can improve operating performance by focusing on the
uninterrupted flow of products and materials

Questions On Tech 145 Lean Manufacturing Essay
ZapLabs for Tech 145 Lean Manufacturing Professor: David Steele Submitted by Brandon Anstett,
Bruck Tesfaye, Harjas Rakhra, and Stephan Daniels 12/13/2016 1 Index 1.
Introduction......................................................................... 3 a. 1.1) Statement of the
Problem........................................... 4 b. 1.2) Purpose of the Study............................................... 4 c.
1.3) Assumptions of the Study.......................................... 4 d. 1.4) Limitations of the
Study............................................ 5 2. Methodology...................................................................... 5 3.
Result............................................................................... 6 a. 3.1) Current State Value Stream Map
Analysis........................ 6 b. 3.2) Future State Value Stream Map Analysis......................... 10 4.
Discussion.......................................................................... 12 5. Time
Log........................................................................... 12 6.
Conclusion.......................................................................... 13 2 Introduction Today there is a huge
demand for information technology in most types of business. With so much demand, there is also a
huge cost involved when implementing IT solutions to a business. Because of this, most IT
departments are trying their best to offer low cost, high quality solutions. The research done for this
project focuses on ways to reduce overall lead time in the software development cycle for the
software manufacturing company ZapLabs. By reducing the lead time involved in receiving and
completing tickets from customers, ZapLabs can reduce costs while offering a more quality product
based on each individual customer 's needs and requests. In order to identify, sort, and resolve issues
in the process flow that can bring the

Advantages And Disadvantages Of Lean Manufacturing
Introduction
Lean manufacturing is an incorporated socio–technical framework, which involves a bundle of
administration practices that can be connected to dispose of the waste and diminish the variability of
suppliers, clients and inside assets and procedures (Anvari, Zulkifli, Yusuff, Ismail, & Hojjati, 2011)
Lean manufacturing idea has been broadly acknowledged in the administration and assembling
businesses. Various written works have explored the Lean advantages and applications. The term
Lean was initially instituted by Krafcik (1988). Therefore, Womack, Jones, and Roos (1991) utilized
the term Lean implementing to portray the Toyota creation framework (TPS).
Womack and Jones (2003) expressed that Lean standards can be connected in any industry.
Distinctive sorts of associations have actualized Lean fabricating. By and by, Marvel and Standridge
(2009) contended that couple of ... Show more content on Helpwriting.net ...
The activities could be gathered into five classes: theoretical systems, execution structures, guides,
and graphic and evaluation agenda. The order of these classes results from the name and qualities of
every activity given in the writing. Some examination studies may delineate their execution prepare
as elucidating style. For instance, Jina et al. (1997) recommended an unmistakable chart in applying
Lean standards to suit the high assortment low volume circumstance. The chart has three interrelated
segments: item plan adapted to logistics and assembling, arranging assembling along Lean
fabricating standards and integrative supplier connections. Womack and Jones (2003) depicted a
period structure for an Lean jump. It incorporates four stages: get begin, make another association,
introduce business frameworks and complete the change. Shah and Ward (2003) characterized the
accomplishment of Lean execution as it relies on upon three hierarchical components: plant age,
plant size and

Lean Manufacturing With Kanban System Implementation
Lean Manufacturing with Kanban System Implementation
Abstract Article one is about Application of kanban system for managing inventory and it states that
Lean manufacturing is a culture in which all employees continuously look for a Ways to improve
processes. The present article also states that how company can use this tool for managing the
inventory.
Article two is about Application of Kanban system for implementing lean manufacturing and it
provide a background on lean manufacturing, present an overview of manufacturing wastes and
introduce the tools and techniques that will help companies for future betterment . Manufacturing
approach is to be on cost reduction by eliminating Non– Value added activities that the idea of lean.
This paper provides an overview of implementation of lean manufacturing in Engine valve
machining cell in a leading auto components manufacturing industry.
Article three is about Lean manufacturing case study on kanban implementation and it states that the
objectives of this case study is to determine how does the Kanban system works effectively in
multinational organization. This also gave idea on the study suggest that inventory management, top
management commitment, vendor participation, and quality improvement are important for Kanban
deployment and towards lean manufacturing.
Introduction
Lean manufacturing is a process used in manufacturing organizations to increase competitive
advantage.
Toyota has developed better ways to

The Evolution Of Lean Manufacturing
LEAN MANUFACTURING
Origins of Lean Lean originally originated from Total Productive Maintenance (TPM) (McCarthy,
2015) in the early 1900's however it wasn't until the Toyota family introduced the Toyota Production
System (TPS) into their company manufacturing operations that it began to gain recognition. In the
1950's, Toyota first implemented quality measures within the production lines process and hence the
initial stages of continuous improvement. Taiichi Ono, who was the executive vice president,
developed and implemented the renowned Toyota Production System (TPS) after the Second World
War as a means of producing a highly effective and efficient manufacturing line for their products.
Ono took great inspiration from Henry Ford's early lean concepts and applied it to meet the demand
of their own Japanese market. This built the seeds of TPS, which today is better known as lean
manufacturing (Womack&Jones, 1996). Nowadays, Lean is used globally throughout industry in all
different sizes of enterprises that can depend on the successful implementation of Lean. (Herron,
2008). Toyota's success as one of the world's largest automotive manufacturers and leading Lean
implementers stands as proof of Leans merits. (Institite, 2000–2016). This has led to enormous
demand for knowledge on leans tools and techniques as companies continue to have success with its
implementation.
What is Lean? Lean is commonly referred to as a systematic methodology to approaching and

Lean Manufacturing
Introduction to Lean manufacturing:
Principles of lean thinking have been broadly accepted by many manufacturing operations and have
been applied successfully across many. Different authors define it distinctively. Lean manufacturing
is most frequently associated with the elimination of seven important wastes to ameliorate the
effects of variability in supply, processing time or demand defined it as a philosophy of
manufacturing that focuses on delivering the highest quality product on time and at the lowest cost.
Worley (2004) defined it as the systematic removal of waste by all members of the organization
from all areas of the value stream. Briefly, it is called lean as it uses less, or the minimum of
everything required to produce a ... Show more content on Helpwriting.net ...
Lean manufacturing requires machines which are reliable and efficient. Inventories can be reduced
when machine downtime is minimized.
Work processes across the value stream should also be emphasized in lean manufacturing. Processes
should be performed with a minimum of non value added activities in order to reduce waiting time,
queuing time, moving time, and other delays Besides this, standardization of work processes is
needed to facilitate efficient, safe work methods and eliminate wastes, while maintaining
quality.Itensures a consistent performance and creates a foundation for continuous improvement.
Nowadays, a product with high quality is a prerequisite for any manufacturer. Quality is a major
focus in lean manufacturing because poor quality management would result in many wastes such as
scraps and rejects. Appropriate quality management helps to control a manufacturing process, and
this reduces "safety" buffers and exposes quality issues. Reduction of "safety" buffers will
eventually lead to reduction of inventories.
Employees who are motivated and empowered are essential since people are the key element in lean
manufacturing. Japanese regard people as assets because they are the ones who are going to solve
problems and improve processes in production.
Another key area of lean manufacturing is layout which determines the arrangement of facilities in a
factory.

Sustainability: Lean Manufacturing and Ge Essay
Global OPERATIONS MANAGEMENT
Increasing demand for sustainable supply chainsHow Trend is Affecting Global Company General
Electrics (GE) Mentor: Professor Steef van de Velde
OneMBA class 2014, Team – 6
Basant Singh, UNC
Nicole Wachs, UNC
Omar Castillo, UNC
Jonathan Tamayo, EGADE
Eduardo Palma, FGV
Sven Kenis, RSM
Tessa van lperen, RSM
Mentor: Professor Steef van de Velde
OneMBA class 2014, Team – 6
Basant Singh, UNC
Nicole Wachs, UNC
Omar Castillo, UNC
Jonathan Tamayo, EGADE
Eduardo Palma, FGV
Sven Kenis, RSM
Tessa van lperen, RSM
| |
Introduction
The goal of this report was to learn more about a global company's sustainability strategy and
understand how it relates to its international operations. Our ... Show more content on
Helpwriting.net ...
Many companies are now transitioning to the sustainability model because this model provides
different business opportunities but also helps in possibly reducing the operational cost by
introducing LEAN processes as well as may protect business from market and consumer backlash.
This is an important reason for sustainability gaining popularity and is the reason for us picking this
topic for our research [2].
Selection of General Electric as company and corporation background
In order to successfully drive sustainability and improve the triple bottom line, companies have had
to rethink their business models and transform their operations, increasing the need for sustainable

supply chains. A successful company who has successfully made the shift towards sustainable
operations is General Electric (GE). GE has leveraged its operational capabilities and its reach
across multiple industries and locations to emerge, as one of the leaders in sustainability strategy
and this is the reason to pick GE for this project. We wanted to understand the key global operations
initiatives that are enabling GE to develop and grow financially, environmental and socially
sustainable operations. We wanted to understand how they drive a coherent and consistent
sustainability strategy across their

Lean Manufacturing And Its Production
Lean Manufacturing
Most people wouldn't know what Lean Manufacturing was if they hadn't either learned about it or
use it at work. Lean manufacturing is a way to eliminate waste and maximize customer value.
Delivering the right product, in the right quantity, with the right quantity, at the exact time the
customer needs it and at the lowest cost possible is the main goal of lean manufacturing. With lean
manufacturing you can have benefits such as reduced lead times, improved quality, improved on–
time deliveries, less inventory, less space, less human effort, lower costs, and increased profitability.
The concept of lean manufacturing was introduced in Japan, and Toyota Production System was the
first company to use it. Lean manufacturing simply follows the notion that the customer will pay for
the value of services they receive and they will not pay for the mistakes. It was stated in Challenges
in the transformation to lean production from different manufacturing process choice that for Toyota
the focal point is not to make money but to generate value for the customers; money follows
automatically if the customers are satisfied.
The lean production philosophy is currently widely applied globally in industries such as the process
industry, aerospace industry, furniture manufacturing, the textile industry, hospitals, government
agencies, and the service industries. But, there are some principles that need to be followed in order
for companies to become lean. There are

Lean Manufacturing Is The Fundamental Means For The...
Introduction
Manufacturing has been perceived as the fundamental means for the development of the economy.
Always showing signs of changing global environment, which has been posturing difficulties of
intensity and survival to every one of the constituents of the economy. Manufacturers everywhere
throughout the world have constantly confronted uplifted difficulties, for example, rising client 's
interest for better and enhanced items, fanciful interest, and rivalry in business sectors. There is no
mistrust that the manufacturers are continually grasping changes and enhancements in their key
exercises or procedures to adapt to the steadily developing difficulties.
To be more productive is the best way to stay and procure benefit in a ... Show more content on
Helpwriting.net ...
Dutta, 2014).
According to (Homa Sheikh–Sajadieh, 2013) "Waste elimination is one of the most effective ways
to increase the profitability of any business. Processes either add value or waste to the production of
a good or service. The seven wastes originated in Japan, where waste is known as "muda". "The
seven wastes" is a tool to further categorize "muda" and was originally developed by Toyota's Chief
Engineer Taiichi Ohno as the core of the Toyota Production System, also known as Lean
Manufacturing. To eliminate waste, it is important to understand exactly what waste is and where it
exists. While products significantly differ between factories, the typical wastes found in
manufacturing environments are quite similar. For each waste, there is a strategy to reduce or
eliminate its effect on a company, thereby improving overall performance and quality".
The seven types of waste are:
1. Waste from overproduction.
2. Waste from waiting times.
3. Waste from transportation and handling.
4. Waste related to useless and excess inventories.
5. Waste in the production process.
6. Useless motions.
7. Waste from scrap and defects.
According to (Okpala, 2014) "In Lean Production System, waste (which is referred to as muda in
Japan) is described as anything that destroys resources and does not add any value to the customer's
requirements. This is because manufacturing waste is the application of resources like raw materials,
labor, equipment, or machines over and above what is

Disadvantages Of Lean Manufacturing
2– LEAN MANUFACTURING:
As per Womack, Jones, and Roos (1990), the expression "Lean" speaks to a framework that uses
less input with a specific end goal to make the same yields than those made by a conventional large
scale manufacturing framework, while expanding the scope of various completed merchandise for
the end client. The term lean manufacturing is synonymous with various names, for example, agile
manufacturing, just–in–time manufacturing, synchronous manufacturing, world class
manufacturing, and continuous flow (serial production).
Lean manufacturing is an operational procedure arranged toward accomplishing the most limited
conceivable process duration by wiping out waste. It is gotten from the Toyota production system
and its goal is to expand the worth included work by taking out squanders and decreasing
superfluous work. The method frequently diminishes the time between a client request and
shipment, and it is intended to enhance benefit, consumer loyalty, throughput time, and worker
inspiration. The advantages of lean manufacturing for the most part are lower costs, higher quality,
and shorter lead times. The term lean manufacturing is made to speak to less human exertion in the
organization, less assembling space, less interest in apparatuses, less stock in advancement, and less
designing ... Show more content on Helpwriting.net ...
Waste, or MUDA, is anything that adds expense to the item without including esteem. Squanders
can be arranged into seven classes:
1. Waste of overproducing: Producing components that are neither intended for stock nor planned
for sale immediately.
2. Waste of waiting: Refers to the idle time between operations.
3. Waste of transport: Moving material more than necessary.
4. Waste of processing: Doing more to the product than necessary and the customer is willing to

Lean Manufacturing & Six Sigma Manufacturing
DISCUSSION
Lean manufacturing & six sigma Manufacturing:
Six sigma and lean system has the same way of approaching but uses different technology to
achieve the goal. The both procedure lives up to expectations for to dispense with waste and expand
the productivity of the procedure and convey the zero defect items. Recognizable of primary cause
of waste is the fundamental distinction between lean and six sigma. lean innovation says that waste
originates from undesirable steps in the production process which don 't add the value of the final
product while six sigma says that waste is a direct result of variety of diverse procedures.
The focus on lead–time reduction is an simple and effective performance measure to employ (Suri,
1998) where ... Show more content on Helpwriting.net ...
Six sigma has better performance, reduced waste, uniform process output.
Format: Kaizan event format concentrated resources in short time frame. Six sigma has project
format. Resources spread over months.
Scope and Scale: Lean has quick and initial gains, ongoing improvement, suitable for every one and
every part of the business. The scope and scale of six sigma is help to analysis the complex
problems that require in depth analysis. http://improveconsulting.biz/?page_id=154
Lean manufacturing and Theory of Constraints:
The hypothesis of constraints may be an extremely powerful technique for shop floor administration
for a few manufacturers, however in numerous mass customization circumstances it will be hard to
execute because of its substantial dependence on a steady and consistent constraint in the system. At
the point when considering the capacity of TOC to help in making productive mass customization, it
is vital to consider the high variability that will be available. It has been found that once the DBR
component is actualized, the constraint can shift because of variety in the system (Goldratt, 2004),
and these occasional shifts must be recognized and the system adjusted likewise. With mass
customization, numerous organizations will manage high work content variety from every work
piece to the following, accordingly it is likely that the constraint will shift oftentimes, with a higher
impact for low volume

Lean Manufacturing Essay
1
INEN 5354 Lean Manufacturing–Course Project
Due Date: August 15, 2015
A Project on
A COMPARISON AND CONTRAST OF IMPLEMENTATION OF LEAN MANUFACTURIG IN
A FOOD INDUSTRY AND A HEALTHCARE INDUSTRY
Submitted by
Ranjith Kumar Gandi– L20384478
Krishna Chaintanya Kurra– L20369514
Under the Guidance of
Dr. Berna Eren Togkoz
2
:: TABLE OF CONTENTS ::
 Introduction...................................................Page no.3
 Brief description and Literature explanation of a Food Industry and a HealthCare
system.........................................................Page no.4–8
 Comparing and contrasting the implementation of Lean Manufacturing in manufacturing and
service industries:...................................................Page no.8–9 ... Show more content on
Helpwriting.net ...
Later on, many service industries have adopted the philosophy of Lean with the aim of improving
their quality of service, processes, methods and resulting a better customer satisfaction. The study
made revealed that although the Lean Manufacturing was designed and developed for the
manufacturing industries initially, it is now proven that even the service industries could implement
the Lean principles as well, and increasing the customer satisfaction.
In this project, we compare and contrast how lean manufacturing principles and its best practices
have been applied in the Food industry (manufacturing industry) and the Health Care and Hospital
systems (service industry).
4
Brief description and literature explanation of the Industries selected:
 Manufacturing Industry–FOOD INDUSTRY:
The food and beverage industries have large batch processes .There is a misperception that Lean
Manufacturing do not lead to easy application in these industries. Food industry is composed of
various sectors such as meat and fish, vegetables and fruits, dairy and its products, bakery, oils and
fats, coffee and cocoa products, sugar and salt, cocoa and its products, canned foods, and alcoholic
and non–alcoholic beverages, etc. The food industry represents more than 20% of the total industry.

These products are sold to customers not on orders. The food products are manufactured based on a
forecast of the market and demand, and this results in large differences between the forecast made
and

Lean Manufacturing Is An Approach
Introduction Lean Manufacturing is an approach taken by manufacturing organization to increase
efficiency through optimization and maximize customer value while minimizing waste.
Traditionally, Lean principles were applied to manufacturing industries especially automotive
companies. However, with the success in automotive industry, it no longer limited to automotive
sector and can be applied in other manufacturing sectors as well as services industries (Balle, et al.,
2006). The drivers for implementing Lean in both manufacturing and service sectors are customer
demands for better quality products and services, managerial demands for cost reduction and
sustaining in an increasing market competitiveness. Lean implementation and various success
stories has led companies worldwide to introduce lean in their operations and services but majority
of these companies achieved only modest levels of success (Womack & Jones, 2003). It is reported
that many organizations are not able to transform themselves to lean organization and thus at some
point of time, lean implementation is destined to fail (Farris, et al., 2009). Some of the main factors
for lean failures are poor communication, lack of strong leadership, lack of learning, staff resistance
to change, and lack of clear direction (Emiliani & Stec, 2005). Researchers have argued that
transition to lean environment and sustaining lean improvements requires cultural change in the
organization rather than changing the

Research Paper On Lean Manufacturing
Lean Manufacturing
Avery Mitchell – R00096646
"It's not necessary to change, survival is not mandatory" – Demming
Lean manufacturing a systematic approach to doing more with less. In other words, Lean, is a
method of increasing the amount of a manufacturer's output, while reducing the amount of resources
put in. Lean is of great interest to manufacturers around the world. Companies of all sizes employ
lean principles to employ large improvements to quality, marketability and customer service.
Lean is a production philosophy, a way of manufacturing a product using less resources. These
principles allow a manufacturer to produce more with less by eliminating waste. Less time,
inventory, capital, resources. This can be accomplished by highlighting ... Show more content on
Helpwriting.net ...
Lean has been applied to many industries and have worked for factories of all sizes. Most factories
have less than 250 employees.
Small batches are used to smooth production flow in the plant.
Total manufacturing effort is divided into value added activities and into non value added activities.
Lean manufacturing aims to reduce the amount of non–value added activities. Optimising flow of
production allows manufacturers to reduce the non–value added activites and increase the value
adding activities.
History
The idea that reducing waste will save money is not a novel one, so lean manufacturing has actually
been around for hundreds of years, for example the idea of an assembly line far predates the modern
lean manufacturing era. However the modern iteration of lean manufacturing was developed in
Japan by Toyoda, the founder of Toyota. The Toyota Production System was translated to English in
1975 and today is used as the starting point of lean manufacturing worldwide.
Many people believe that the Toyota production system was the beginning of Lean manufacturing.
Translated to English in 1975. 1990 researchers learned that Toyota was the most efficient
auomotive systems in the world. The machine that changed the world.

Just in Time System
Kanban

The Problem Of Lean Manufacturing
Again, LT help firm to redesign the patients' pathway. The significant numbers of waste were
eliminated and achieved more efficient process. The patients' pathways were reduced significantly.
From the fact, originally, there were 19 steps in serving patients, but with lean they were reduced to
11. This leads to the deduction in lead time in just 80 minutes [16].
As usual, every theory implemented has its own limitation. For lean thinking, it can help
manufacturing industry to achieve in minimizing the waste activity. However, lean manufacturing
has not been accepted by all users. For instance, difficulty in having human coordination and the
limitation in applicability outside monotonous manufacturing environments are the weaknesses that
... Show more content on Helpwriting.net ...
Moving on to the next word which is process, the word process is defined as the activities that are
planned to establish the outcome for consumers. These activities will be structured and measured
with care and awareness. The word process, according to Davenport [33], can be able to identify
strongly on how job is handled within the business process inside the company.
For the word "Business process" , it can sophisticatedly define into 3 different categories which are
inputs, the processing, and the outcome. These three elements will concern to the process of
inserting input into transformation process. The inputs will be included with data such as consumers'
inquiries and materials. After that the, the processing will transform those data and materials into the
outcome in which they have to move on through a number of processes. These materials might
possibly turn into waste and time consuming if the process is not ready. The outcome, finally, will
be delivered to consumers.
Hammer [35] has further explained the 4 key words for BPR as followed: The first key word is
foundation. In the process of reengineering, members in organization might come up with the most
basic inquiries about these changes and how they function.
The second key word is essential design. This will be focusing on the very foundation of things. The
key word will totally ignore the outermost part that is already good in the moment, but it will
completely

Lean Manufacturing Concept Of Production
Lean Manufacturing Concept
Background
Along with the change in times and technological and diversification enterprises flourishing,
Enterprises face the low cost production in developing countries and globalization competition, to
consolidate market position and sustainable operation and development, the enterprises and
manufacturer must have to strengthen the production management and production technology
system, otherwise it is difficult to profit for enterprises and manufacturer to foothold in the market.
No matter manufacturer, service industry, to deal with these situations and improve market
competitiveness, they need to break the traditional production way. In recent years, the enterprises
and manufacturer toward to adapt lean ... Show more content on Helpwriting.net ...
Useless manpower, less equipment and less time to generate more value is what lean manufacturing
pursuit for (Stenzel, 2007).
Toyota way Toyota develops four main principles to implement Toyota production system
(Krijnen,2007), including:
1. Long–term philosophy: Management decisions must be based on long–term philosophy, even if it
must sacrifice short–term financial goals expense.
2. The right produce process will produce the right results: Create a continuous process flow to bring
problems to the surface, use visual control so no problems are hidden, and the standardization of
work duties is to empower the employees and continuous improvement.
3. Add Value to the Organization by Developing Your People: Cultivate the employee who
thoroughly understand and embrace the concept of the company to be leaders, that they can teach
what they learn to their subordinates, and respect the company 's business partner and supplier
networks, challenge them and help them improve.
4. Continuously Solving Root Problems Drives Organizational Learning: Do not make the decisions
hasty, considering all possible options to reach the consensus then execution fast. Furthermore,
through constant reflection and continuously improvement to become a learning organization.
Though these principles Toyota constantly makes the low waste and high–quality products, that
many industries followed it.
Lean manufacturing Lean manufacturing is the use

Toyota's Lean Manufacturing Process
Prior to Toyota's Production System, the company was efficient, yet could not compete with large
American competitors such as General Motors and Ford. Therefore, management realized that if the
company was to be successful not only in Japan, but globally it would need to improve its
manufacturing process. Consequently, the company developed Toyota's lean manufacturing process,
which is still used today. The LMP was used to eliminate waste in the entire production process to
become more responsive to market demand and produce high quality products economically. In
order to provide superior products, Toyota implemented many revolutionary strategies. For example,
the company started, or invented, the Just–in–Time Manufacturing process. The JIT process,
according to our text, is used to reduce inventory costs by scheduling supplies to arrive just in time
to enter the production process or as inventory stock is depleted (Hill et al., 2015). Toyota used the
just–in–time system to improve its supply chain management, which drastically decreased costs and
increased the company's production facilities output as compared to its competitors. In addition to
JIT, the company introduced a concept known as Kanban that was included within the new JIT
system. The Kanban system was developed by Ohno and was used to arrange for components and/or
assemblies manufactured at Toyota to be delivered to the assembly floor only when needed, not
before (Hill et al., 2015). Essentially the Kanban

Lean Vs Lean Manufacturing Systems
Executive Summary Lean Manufacturing Systems were first introduced in Japan by the Toyota
Motor Corporation. The Lean movement is a type of a system that relies on simple visual cues in
order to manage production stages that are based on customer demand. The system is a is also a kind
of manufacturing that put great emphasis on the minimization of resources, time included, that is
utilized in various activities of manufacturing and provides techniques for uninterrupted quality
improvement. Although this system has gained enormous momentum and respect over the last
decades, some companies have found it difficult to use Lean Manufacturing Systems, and, as a
result, the companies have ended up failing. The concept of Lean Systems is best understood when
companies familiarize themselves with certain key insights that are utilized during the course of
systems architecting. The article provides a synopsis of the lean and is divided into four parts that
will be mainly used for the purpose of this review.
The article starts by comparing Lean Systems used in Japan compared to the ones used in the west.
The success of lean production has induced mass producers to copy many of its features, but it is not
always successful (Maier and Rechtin, 2002, p.70). The success of Japanese in using lean
production can be linked to the limitation of conversion of lean systems in other environments. In
the West, industrial engineers and management science people

Lean Manufacturing And Six Sigma
Q3. 1. Introduction In today's world, majority of the enterprises are driven through customers' need
whose primary emphasis is on quality. Hence there is a need for continuous process improvement to
satisfy the need of the customers. Lean Manufacturing and Six–sigma approach has been applied in
diverse manufacturing processes which in–turn has contributed significantly in achieving continuous
improvements. By utilizing these tools, organizations focus on maximizing their bottom–line
successes apart from improving their top–line growth. However, many organizations face difficulties
while imparting these tools in their sophisticated business models. 2. Lean Six–sigma Methodology
2.1 Lean Management in Toyota Lean principles are developed ... Show more content on
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These methods were utilized by Toyota to control their inventory levels and making their
manufacturing process more cost effective. Apart from Manufacturing, Lean principles can be
applied in every other aspect of the supply chain. Figure 1: Lean Enterprise [2] Figure 1 provides a
conceptual framework of lean principles across the supply chain of the enterprise thereby yielding
value to the customer. Lean thinking helps in providing flexibility to the needs of the customer.
Emphasis is also put on organization of workplace which leads to more simplified work
environment. Ease of access in the workplace and good ergonomic designs are some of the by–
products of lean thinking methodology. Lean enterprises are more adaptable to changing market
trends and also provide prompt delivery to products and services. [3] 2.2 Six–sigma Approach Six–
sigma is considered as a structured approach to solving problems. It provides a statistical analysis to
quality improvement in production processes. There are primarily five phases in this approach
namely: define measure, analyze, improve and control, widely mentioned as DMAIC approach. The
pattern of DMAIC ensures that the projects are focused on current problem and in providing the
management with consistent and deliverable results. In the Define Phase projects are identified
through brainstorming within the organization. Project goals are set and the available resources are
allocated for the

Lean Manufacturing
Insert your college logo here
UNIVERSITI UTARA
MALAYSIA
REZZEN PENANG
TERM PAPER:
Lean Manufacturing
PREPARED BY: Your Name Student ID
PREPARED FOR: Lecturers Name
DATE OF SUBMISSION: Date going to submit
Table of Content
1.0 Introduction 1.1 Jabil Vision 1.2 Jabil Mission 2. History of lean manufacturing 1. What is lean
manufacturing 2. Primary elements for lean manufacturing 3. Issues in lean manufacturing 3. 7
types of waste 1. Overproduction. 2. Waiting 3. Transporting 4. Inappropriate Processing 5.
Unnecessary Inventory 6. Unnecessary / Excess Motion 7. Defects 8. ... Show more content on
Helpwriting.net ...
❖ Mechanical Design: Jabil Circuit's mechanical engineering design team involves in three–
dimensional design and analysis of electronic and optical assemblies using modeling and analytical
tools. It also involves in industrial design, advance mechanism development, and tooling
management. ❖ Computer–Assisted Design: Jabil Circuit's computer–assisted design (CAD) team
provides PCBA design services using advanced CAD/computer–assisted engineering tools, PCBA
design testing and verification services, and other consulting services, which include the generation
of a bill of materials, approved vendor list, and assembly equipment configuration for a particular
PCBA design. ❖ Product Validation: Jabil Circuit's product validation team provides product and
process validation. This includes system test, product safety, regulatory compliance, and reliability.
❖ Product Solutions: Jabil Circuit's product solutions efforts are focused on providing system–based
solutions to engineering problems and challenges on the design of new technologies and concepts in
specific growth areas as a means of expanding its customer relationships. Jabil Circuit's design
centers are located in Vienna, Austria; Hasselt, Belgium; Beijing and Shanghai, China; Colorado
Springs, Colorado; St. Petersburg, Florida; Jena, Germany; Tokyo, Japan;

The Pros And Cons Of Lean Manufacturing
Introduction: The idea behind the lean manufacturing is to work relentlessly on eliminating waste by
the end of the manufacturing process. As stated by Cirjaliu and Draghici, (2016), lean
manufacturing works as a collection of a number of tools, techniques and tips that proves effective
for driving the wastes generated during the manufacturing process. Lean manufacturing as it is also
known as Toyota Production System is one of the most basic and systematic form of waste
elimination system.
Lean manufacturing has become one of the most acceptable forms of manufacturing technique
among the various manufacturers. The aim of the report is to analyze the advantages and limitation
of the lean manufacturing process. A detail analysis of the system will be done by referring to a
number of scientific journals based on the same topic.
Analysis of the production technique: Lean production is all about gaining more by doing less, such
as less time, limited fund and labor and also within a small space. Thus, five major areas that drive
the lean manufacturing process are its quality, cost, kind of delivery, safety and morale. By the
means of lean manufacturing, a number of advantages can be achieved. These advantages are:
 Reduction of waste by 80%
 Production cost is reduced by almost 50%
 Flexibility of the system increases
 Labor cost gets reduced by at least 50% (Bhamu & Singh Sangwan, 2014)
 Capacity of the current facilities increases by 50% as well
 Reduction of

Lean Manufacturing Is A Method Of Reducing Waste
1) INTRODUCTION: Lean manufacturing is a method of reducing waste (muda) in the
manufacturing system. It also considers the waste due to overload and waste dude to over burden.
Lean manufacturing also best known as Toyota production system or kaizen production system.
Although the Toyota production system was introduced more than a century ago it has continue to
develop over time. It was practiced by the Henry Ford for the manufacturing of Ford model T which
was very successful between the years 1908 to 1920 which almost sold 2 Million cars a year. Later
on it was developed by the Toyota in Japan. The main idea behind the lean manufacturing is to value
the customer needs by reducing the waste and achieving good products with more value by
consuming less resources. Muda is defined as the material or the activity for which the customer is
not willing to pay. The main task of lean manufacturing is to identify Muda and to get rid of it.
These products are created by using less human effort, less space, less capital, less time to produce
high quality.
There are eight kinds of Muda mentioned in Lean manufacturing:
1. Waste due to unwanted motion
2. Waste due to waiting
3. Waste of conveyance
4. Waste due to correction
5. Waste due to over production
6. Waste due to over processing
7. Waste of Inventory
8. Waste due to knowledge disconnection
There are five steps that represent a continue cycle that leads to successful implementation of lean
manufacturing.
1. Specify value

Lean Manufacturing Outcomes Essay

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