...1.0 INTRODUCTION The requirement is to review a current article or situation relating to lean manufacturing or Toyota production system. 1.1 PURPOSE The purpose of this assignment will provide an opportunity to evaluate the content and quality of an article or situation. 1.2 DEFINITIONS Andon A visual management tool that highlights the status of operations in an area at a single glance and that signals whenever an abnormality occurs. An andon, which is the Japanese term for “lamp,” can indicate production status (for example, which machines are operating), an abnormality (for example, machine downtime, a quality problem, tooling faults, operator delays, and materials shortages), and needed actions, such as change overs. Five Whys The practice of asking why repeatedly whenever a problem is encountered in order to get beyond the obvious symptoms to discover the root cause. The specific number five is not the point. Rather it is to keep asking until the root cause is reached and eliminated. Heijunka Japanese technique of achieving even output flow by coordinated sequencing of very small production batches throughout the manufacturing line in a lean production or just in time (JIT) system. Jidoka Japanese term that provides machines and operators the ability to detect when an abnormal condition has occurred and immediately stop work. This enables operations to build in quality at each process and to separate men and machines for more efficient work. Jidoka...
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...Wastes to be eliminated are overproduction, excess inventory, delay, transportation, rework, underutilization of people and facilities. Wastes should be eliminated to achieve better connectivity between operations. It improves response time to customer demand, reduces inventories, reduces working capital requirements, improves productivity. It is executed by using various lean tools such as 5S, Value Stream Mapping(VSM), Kanban and Kaizen.This paper mainly uses Value Stream Mapping (VSM) and layout changes to solve...
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...doi:10.3926/jiem.2010.v3n1.p11-32 JIEM, 2010 – 3(1): 11-32 – Online ISSN: 2013-0953 Print ISSN: 2013-8423 A case study of lean, sustainable manufacturing Geoff Miller1, Janice Pawloski2, Charles Standridge 3 1 Grand Rapids Chair Company (USA); 2, 3 School of Engineering, Grand Valley State University (USA) geoff@grandrapidschair.com; pawloskj@gvsu.edu; standric@gvsu.edu Received December 2009 Accepted May 2010 Abstract: A small furniture production company has integrated lean tools and sustainability concepts with discrete event simulation modeling and analysis as well as mathematical optimization to make a positive impact on the environment, society and its own financial success. The principles of lean manufacturing that aid in the elimination of waste have helped the company meet ever increasing customer demands while preserving valuable resources for future generations. The implementation of lean and sustainable manufacturing was aided by the use of discrete event simulation and optimization to overcome deficits in lean’s traditional implementation strategies. Lean and green manufacturing can have a more significant, positive impact on multiple measures of operational performance when implemented concurrently rather than separately. These ideas are demonstrated by three applications. Keywords: lean manufacturing, green manufacturing, case-study, discrete event simulation, optimization 1 Introduction Manufacturers are under tremendous pressure to...
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...Protection Agency Solid Waste and Emergency Response (5302W) Policy, Economics & Innovation (1807T) EPA100-R-03-005 October 2003 www.epa.gov/ innovation/lean.htm Lean Manufacturing and the Environment: Research on Advanced Manufacturing Systems and the Environment and Recommendations for Leveraging Better Environmental Performance ACKNOWLEDGMENTS This report was prepared for the U.S. Environmental Protection Agency's Office of Solid Waste and Emergency Response (OSWER) and Office of Policy, Economics, and Innovation (OPEI). Ross & Associates Environmental Consulting, Ltd. prepared this report for U.S. EPA under contract to Industrial Economics, Inc. (U.S. EPA Contract # 68-D9-9018). DISCLAIMER The observations articulated in this report and its appendices represent Ross & Associates’ interpretation of the research, case study information, and interviews with lean experts and do not necessarily represent the opinions of the organizations or lean experts interviewed or researched as part of this effort. U.S. Environmental Protection Agency (EPA) representatives have reviewed and approved this report, but this does not necessarily constitute EPA endorsement of the observations or recommendations presented in this report. Lean Manufacturing and the Environment: Research on Advanced Manufacturing Systems and the Environment and Recommendations for Leveraging Better Environmental Performance Table of Contents Executive Summary . . . . . . . . . . . . . . . . ....
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...MSRSAS - Postgraduate Engineering and Management Programme - PEMP
Module Code Module Name Course Department
EMM515 Lean Operations and Management of Lean Organizations M.Sc. in Engineering and Manufacturing Management Mechanical and Manufacturing Engg .
Name of the Student Reg. No Batch Module Leader
Liju G BUB0912004 Full-Time 2012. SANDEEP. N
M.S.Ramaiah School of Advanced Studies
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...[pic] Case Study #1 Submitted by: Team #2 Fernanda G. Isidoro Correa Henrique Siqueira Madeira Rafael Frasson Pereira Rafael Gomes de Carvalho MSE 507 Prof. Scott Wainess Date 10-08-14 Table of Contents 1. The Lean Implementation 2. The Five Principles of Lean a. Specifying Customer Value b. Identifying the Value Stream c. Making the Value Stream Flow d. Implementing Customer Pull e. Pursuing Perfection 3. Insights and Conclusions 4. Appendix The Lean Implementation As we have studied, lean manufacturing is one of the initiatives that many major businesses in the world have been trying to adopt in order to remain competitive in an increasingly global market. The focus of this approach is on cost reduction by eliminating non value added activities. Applications of lean manufacturing have been less common in the continuous / process sector, in part because of a perception that this sector is less amenable to many lean techniques, and in part because of the lack of documented applications. This has caused managers to be reluctant to commit to the improvement program. The chosen article for this case study takes a case based approach to address both issues. It describes a case in which lean principles were adapted for the continuous / process sector for application at a large integrated steel mill. Value stream mapping was the main tool used to identify the opportunities...
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...Journal A systematic review of Lean Six Sigma for the manufacturing industry Saja Ahmed Albliwi Jiju Antony Sarina Abdul halim Lim Article information: Downloaded by North South University At 22:57 26 January 2016 (PT) To cite this document: Saja Ahmed Albliwi Jiju Antony Sarina Abdul halim Lim , (2015),"A systematic review of Lean Six Sigma for the manufacturing industry", Business Process Management Journal, Vol. 21 Iss 3 pp. 665 - 691 Permanent link to this document: http://dx.doi.org/10.1108/BPMJ-03-2014-0019 Downloaded on: 26 January 2016, At: 22:57 (PT) References: this document contains references to 63 other documents. To copy this document: permissions@emeraldinsight.com The fulltext of this document has been downloaded 961 times since 2015* Users who downloaded this article also downloaded: Saja Albliwi, Jiju Antony, Sarina Abdul Halim Lim, Ton van der Wiele, (2014),"Critical failure factors of Lean Six Sigma: a systematic literature review", International Journal of Quality & Reliability Management, Vol. 31 Iss 9 pp. 1012-1030 http://dx.doi.org/10.1108/IJQRM-09-2013-0147 M.P.J. Pepper, T.A. Spedding, (2010),"The evolution of lean Six Sigma", International Journal of Quality & Reliability Management, Vol. 27 Iss 2 pp. 138-155 http:// dx.doi.org/10.1108/02656711011014276 Diego Pacheco, Isaac Pergher, Guilherme Luís Roehe Vaccaro, Carlos Fernando Jung, Carla ten Caten, (2015),"18 comparative aspects between Lean and Six Sigma: Complementarity ...
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...Lean Management In Automobile Industry Lean Management In Automobile Industry Arvinder Singh, Bargavi Poloju, Inderpreet Kaur, Inderjeet Kaur, Jaskaran Singh Gill Eastern Institute of Technology September 10, 2015 Abstract Lean and six sigma are widely known business improvement processes for industries /organisations these days for achieving drastic results, which are majorly cost cutting, quality maintenance and time management by specializing in processes to boost performance. Nowadays, There are some industries that are even integrating lean and six sigma into a more cohesive strategy i.e., lean sigma in order to establish even more powerful and effective process which focuses at eliminating wasteful activities and retaining most of the strengths of each activity. Lean Sigma aims to combine waste eliminating strategies of Lean Thinking with variability reducing techniques of six sigma to promote growth and increase revenue from the bottom line of organisations(M. Kumara). Lean management is outlined as a consistent and a methodical approach to determining and eliminating waste through continuous improvement, flowing the merchandise at the pull of the client in pursuit of perfection. The idea of lean management was developed for maximizing the resource utilization through reduction of waste, and eventually lean was developed in response to the unsteady and ever-competitive business organisations. For organisations to face major challenges and competition can be...
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...Int. J. Mgmt Res. & Bus. Strat. 2013 Jaskanwal Singh Mand et al., 2013 ISSN 2319-345X www.ijmrbs.com Vol. 2, No. 1, January 2013 © 2013 IJMRBS. All Rights Reserved APPLICATION OF LEAN AND JIT PRINCIPLES IN SUPPLY CHAIN MANAGEMENT Chandan Deep Singh1, Rajdeep Singh1, Jaskanwal Singh Mand1* and Sukhvir Singh1 *Corresponding Author: Jaskanwal Singh Mand, mandjaskanwal@yahoo.com Supply Chain Management is a set of synchronized decisions and activities utilized to efficiently integrate suppliers, manufacturers, warehouses, transporters, retailers, and customers so that the right product or service is distributed at the right quantities, to the right locations, and at the right time, in order to minimize system-wide costs while satisfying customer service level requirements. SCM leads to a proficient way of doing things completely. Lean manufacturing and JIT play an importunate role in better functioning of SCM. Some of the lean manufacturing principles are: JIT inventory principle, JIT production principle, JIT human resource principle, JIT quality principle, JIT supplier relation principle, The present research involves role of lean manufacturing and JIT principles in SCM. Keywords: SCM, JIT, Lean manufacturing origin of the concept of lean or lean thinking cannot be easily assigned to any one person, company, INTRODUCTION Supply Chain Management (SCM) is a set of synchronized decisions and activities utilized to efficiently integrate suppliers...
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...National University, San 56-1, Sillim-dong, Kwanak-gu, Seoul, Korea Received 20 May 2004; received in revised form 3 October 2005; accepted 1 November 2005 Available online 19 January 2006 Abstract Manufacturing plant managers have sought performance improvements by adhering to the guiding principles of leanness and agility. Lean manufacturing and agile manufacturing paradigms have also received considerable attention in operations management literature. However, paradoxically, the extant literature is lacking in clarity and fails to delineate with sufficient precision how and why leanness and agility differ. Given the resource constraints within which most manufacturing firms have to operate today, it is useful, if not critical, to develop a good understanding of how these paradigms differ and what their constituent dimensions are. Such an understanding is also essential for developing and testing theories relating to leanness and agility. Through a literature review we discuss leanness and agility in two ways: (1) as manufacturing paradigms and (2) as performance capabilities. Our empirical study attempts to determine whether lean and agile forms occur with any degree of regularity in manufacturing plants. The results confirm the existence of homogeneous groups that resemble lean and agile performing plants, and they identify important differences pertaining to their constituent performance dimensions. The results indicate that while the pursuit of agility might presume...
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...Comparing lean and agile logistics strategies: a case study Ruth Banomyong* & Nucharee Supatn Thammasat Business School Thammasat University BANGKOK 10200, THAILAND Abstract The purpose of this paper is to compare the effect of lean and agile strategies on the manufacturing process of an aquarium manufacturer. Numerous studies has demonstrated the benefits of lean and agile strategies in enhancing the competitiveness of firms but none has really discussed or compared how performance differed when utilizing either strategies. Lean strategy can reduce, or even eliminate waste in the production process but lean might not be able to respond to fluctuation in customer demand while agile strategy enhance the responsiveness of the manufacturer. The results of this research show that both strategies provide different types of impact for the manufacturer. The findings also suggest that the manufacturer should not select either a lean or agile strategy but rather to combine both strategies. Keywords: lean, agile, manufacturing strategy, case study, Thailand * Corresponding author. He can be contacted at: Banomyong@thammasat.net 1 Back to "Search By Author" Background The aquarium industry and in particular an aquarium manufacturer in Thailand has been chosen in this paper as the study object for the implementation of a lean strategy versus an agile strategy. The purpose of this paper is to compare the effect of lean and agile strategies on the manufacturing process...
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... | |Course code |LEANM | |Course name |Lean Management | |Course version |1 | |A. The location of the course in the study system | |Level of education |Under graduate | |Degree level |Bachelor | |A form of study |Fulltime | |Field of study |Management | |Profile of study |general academic | |Specialization | - - - ...
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...Comparing lean and agile logistics strategies: a case study Ruth Banomyong* & Nucharee Supatn Thammasat Business School Thammasat University BANGKOK 10200, THAILAND Abstract The purpose of this paper is to compare the effect of lean and agile strategies on the manufacturing process of an aquarium manufacturer. Numerous studies has demonstrated the benefits of lean and agile strategies in enhancing the competitiveness of firms but none has really discussed or compared how performance differed when utilizing either strategies. Lean strategy can reduce, or even eliminate waste in the production process but lean might not be able to respond to fluctuation in customer demand while agile strategy enhance the responsiveness of the manufacturer. The results of this research show that both strategies provide different types of impact for the manufacturer. The findings also suggest that the manufacturer should not select either a lean or agile strategy but rather to combine both strategies. Keywords: lean, agile, manufacturing strategy, case study, Thailand * Corresponding author. He can be contacted at: Banomyong@thammasat.net 1 Back to "Search By Author" Background The aquarium industry and in particular an aquarium manufacturer in Thailand has been chosen in this paper as the study object for the implementation of a lean strategy versus an agile strategy. The purpose of this paper is to compare the effect of lean and agile strategies on the manufacturing process...
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...Inventory Management||||| 5.0| Lean Manufacturing||||| 6.0| Supply Chain Management||||| 7.0| Conclusion||||| References||||| 1.0 Introduction The success of Toyota Motor Company is due to the unique reduction systems that focus on continuous improvement and just in time management. Toyota has created a decentralised structure that encourages employee participation and team working. Toyota incorporated concepts just as supply chain management and inventory management to create high quality automobiles and gain a competitive edge in the highly competitive global automobile market. Toyota’s success and its lean manufacturing philosophy have been widely studied. The Toyota manufacturing system is centred on achieving a high level of productivity. The company has a unique approach to problem solving and it continuously trains its employees. The Toyota Production Systems is based on the lean manufacturing philosophy that seeks to minimize wastages and centres on cost reduction. The Toyota manufacturing philosophy emphasises on quality management through a process of continuous improvement. This report looks at how Toyota created its manufacturing system and the role of operation management techniques to enhance efficiency. This report examines the production processes and philosophy and Toyota to assess how the company has achieved a competitive advantage globally. The lean manufacturing philosophy pioneered by Toyota has...
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...Quality in an integrated Steel Plant – a case study Name of the Scholar : O. Rama Mohan Rao AGM (Pers), Visakhapatnam Steel Plant Dept : Mechanical Engineering Name of the guide : Dr. K.Venkata Subbaiah, Ph.D, Professor in Mech. Engg., Andhra University Dept : Mechanical Engineering ABSTRACT Globalization is making most of the organizations, sectors more intensely competitive. Many organizations are struggling to improve their operating performance in response to market demands for lower costs, higher-quality products and services, shorter lead times, and higher returns on investment in infrastructure and resources. To address issues of competitiveness and to uncover hidden value, our clients find that Lean Six Sigma technique is one of the most powerful platforms available. This research addresses the application of Lean and Six Sigma tools to increase the productivity and improve the quality in the steel industry. It illustrates the procedures of implementing lean tools in a process industry with emphasis on Value stream mapping, 5 s and six sigma tools. Study on Integrated applications of lean & six sigma tools in a continuous process industry are limited. The thesis hypothesizes that there are lot of opportunities for improvement in the process industries like steel if lean and six sigma tools are integrated and utilized. It systematically demonstrates how lean manufacturing tools when used appropriately can help the...
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