2. Q1. Research Title: Lean Management.
Research question: How to implement Lean Management in different sectors
internationally?
Objectives:
1. To state “Lean Management” philosophy.
2. To understand “Lean Thinking” as a proven strategy for managing plants
and factories internationally.
3. To understand the concept of Muda, Mura and Muri.
4. To gain knowledge of various Lean tools and practices and implementing
them in service sector.
Q2. These sets of objectives help us to understand the implementation of Lean
Management in different sectors. Clear objectives can serve as guideposts
throughout the research process from discussion to presentation. Before
implementation of lean management to various sectors it is important to understand
its philosophy. The management of Muda, Mura and Muri is the essential part of
lean management. The use of lean management tools is the crucial part of its
application.
3. Q3. The topic I have chosen is of my interest as it has been a part of my
undergraduate course. I have studied “Lean Management” as an additional subject
under BSI (British Standard Institution). As a mechanical and automation
engineer, I can implement lean thinking in manufacturing processes.
Q4. RELATIONSHIPS AND THEORY
Relationships, as the name suggests is the simple relation between two things
which can or cannot be true. A relationship usually not supported by findings or
logic is just a statement which maybe proved to be true.
A THEORY on the other hand is a relationship, which is supported by logic
behind. In other words theory is something which maybe correct and can be proved
with logic.
For example, “The number of televisions in India is equal to the number of people
in India”. This is a relationship with no logic.
“The number of students in the class are equal to the number of tables people in
India.”
Q5. To gain the knowledge of this topic we must understand the lean management
philosophy in the primary stage.
Any organization has the following ultimate goals:
1. Making profits.
2. Survival
3. Growth
4. Organizational Challenge:
The challenge is to make
• What the customer wants,
• When the customer wants it,
• A price that the customer is willing to pay.
Now let us concentrate what are customer’s expectations. The customers have
following expectations:
• Much better quality.
• More customized variants.
• Just-in-time delivery.
• Shorter lead times.
• And freedom to order in small quantities.
Now let us understand how companies survived back then which lead to
development of lean management philosophy.
During 1970s,
Japanese were redefining the Manufacturing paradigms. Then they began to
incorporate quality and started working on cost focused strategy.
The major development was the discovery of power of FLOW.
They learned how to use TIME as a new competitive dimension.
All these developments led to the formation of:
5. Toyota Production System.
Lean Management Philosophy
An outcome of study of Toyota Production Systems, by a team of
Researchers in USA, led by James Womack & Daniel Jones.
Their books detailing how Toyota has emerged, as the world’s
most efficient automaker popularized Lean Manufacturing as a
new manufacturing philosophy.
The first book was published in 1990 as
“The Machine That Changed the World”
A management philosophy that demands shorter leadtimes to deliver high quality,
low cost products through improved flow in the value stream is called LEAN
PHILOSOPHY.
Definition of LEAN:
The term “lean” is used because lean
manufacturing uses less labor in the factory, manufacturing space, capital
investment, materials, time between the customer order and the product shipment.
Purpose of Lean Management:
The purpose of Lean Management is to make your Company strong and fast.
• Strong = High performance, repeatable performance.
• Fast = Easily adapts to fluctuations in market conditions.
Understanding MUDA, MURA and MURI:
6. Muda means WASTE.
• Waste refers to any activity that does not add value.
• Waste only adds to time and cost.
• Waste blocks flow
In typical manufacturing process MUDA is seen as:
• Mistakes
• Rework
• Scarp
• Piles of Inventory
• Process occupying lot of space
• Machine Breakdowns
• Unnecessary process steps
MURA
Mura means IRREGULARITY. Whenever a smooth flow of work is interrupted in
an operator’s work, the flow of parts and machines,
or the production schedule, there is mura.
It can occur in:
• Production
• Parts flow
• Equipment usage
• Work done by team members
• Information flow
• Material deliveries, causing shortage or
Overstock.
7. MURI
Muri means STRENUOUS WORK.
• A profusely sweating operator.
• Squeaking sound from the machine.
• A newly hired worker assigned to do the job of a veteran without
adequate training.
Q6. The use of Lean management in International businesses will help in
producing the particular product in a less amount of time or decreasing the lead
time. The main principle of lean management is to decrease the manufacturing
time. Lean tool, lean practices and KANBAN contribute to the swift production
of diverse products.
International students can be benefitted by this research paper as they can adopt the
methods of lean management by understanding about lean tools, lean practices and
for that matter KANBAN as well.
Q7. The three approaches needed are:
1. Literature review.
2. Indebt interviews.
3. Questioners.
I have used OBSERVATIONAL methods in my report.
Q8. While studying abroad, the accessibility to Internet, availability of books in
Library helped us to understand the Topic from core. It wasn’t difficult to gather
knowledge for the research. The lectures helped us gain knowledge of
management. Also, the support of faculty and Amity University made it simpler.
8. Q9. I have obtained the research answer by learning the lean tools, lean practices
and the system of KANBAN. Understanding lean management by first focusing
the LEAN PHILOSOPHY helped in the core understanding of the subject.
Implementing these Lean management Principles have made my research
successful.
Q10. REFRENCES
1. Creating Kaizen culture(2013) by Jon Miller, Mike Wroblewski and Jaime
Villafuerte.
2. The Toyota Production System: Beyond Large scale Production (1988) by
Taiichi Ohno.
3. The Lean Turanaround (2012) by Art Byrene.
4. Toyoto Kata(2009) by Mike Rother.
5. The Toyota Way(2003) by Jeffrey Liker.
6. Understanding Organizational Climate (2000) by Altman.
7. Bringing Lean Principles to service Industries (2007) by David Upton.
8. The Machine that changed the world(1990) bu Wamack.
CONCLUSION
The term “lean” is used because lean manufacturing uses less labor in the factory,
manufacturing space, capital investment, materials, time between the customer
order and the product shipment.
A management philosophy that demands shorter leadtimes to deliver high quality,
low cost products through improved flow in the value stream is called LEAN
PHILOSOPHY.
9. Muda means WASTE. Waste refers to any activity that does not add value. Mura
means IRREGULARITY. Whenever a smooth flow of work is interrupted in an
operator’s work, the flow of parts and machines,
or the production schedule, there is mura.
