|
|
What is Lean Thinking?
The ideas behind what is now considered “lean thinking” began as the Toyota Production System. The term “lean” was introduced in the book The Machine That Changed the World (Womack, Jones & Roos, 1990), which discussed the significant performance gap between the Western and Japanese automotive industries. It described the key elements accounting for superior performance as lean production. The term “lean” was used because Japanese business methods used less human effort, capital investment, floor space, materials and time in all aspects of operations.
What is the basic profile of a "traditional manufacturer"?
• Inventory is built to forecast.
• Inventory is then used to satisfy customer demands.
• Excessive work-in-process (WIP).
• Large batch sizes.
• Focused on a small piece, not the strategic whole.
• Cost-cutting focus.
• Department efficiency matters most.
What are the main concepts of lean and how can they benefit me?
| 1. Quality at the Source - Quality at the source reduces the need for rework and prevents further work (and cost) on a product that is already defective. It also simplifies prevention and repair of defects by placing responsibility on the worker. |
| 2. Management and Workforce Practices - Through effective leadership a company can increase morale and improve communication, cooperation and trust. By creating an environment where all levels of the organization participate in the transformation, employees have a better understanding of the "big picture" and a clearer understanding of business and management decisions. |
| 3. Point-of-Use Storage - Point-of-Use Storage reduces material handling requirements and makes it easier to determine raw material needs due to smaller shipments from vendors. |
| 4. Housekeeping - Good housekeeping removes safety hazards and eliminates waste such as searching for parts and tools or working with poorly maintained equipment. |
Where should we start?
Start by gaining the knowledge. You should experience and observe, through on-site visits and workshops, activities that reinforce lean manufacturing principles. Georgia Tech provides an introduction workshop that introduces the principles of lean manufacturing and how they affect your organization’s bottom line. Your first steps towards a lean enterprise should include:
• Gaining senior management commitment;
• Developing change agent;
• Obtaining lean knowledge;
• Creating a sense of urgency;
• Mapping current value streams;
• Initiating improvement in a kaizen blitz; and
• Expanding your scope. |
|