...White Paper Lean Manufacturing Lean Manufacturing Table of Contents Executive Summary.......................................................................................................................................................................................2 Introduction .......................................................................................................................................................................................................4 Lean Manufacturing—So What? .................................................................................................................................................4 Objectives .................................................................................................................................................................................................6 The Manufacturing Challenge .................................................................................................................................................................7 Globalization and Competitive Pressure ................................................................................................................................7 Mass Production to Mass Customization ...............................................................................................................................7 Shortening Product Life Cycles........................................................................
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...Lean is the concept which starts from removing waste [1]. Lean Production is the practice of mass production in which work is completed in minimum time, in a smaller space, with very few workers, with less equipment, and yet achieves highest level of quality in final product [2]. Since the evolution of Toyota Production System in 1950s [2], the lean movement has been widely accepted in automobile industry. However, acceptance of lean technology in the process industries (steel sector) have been much slower [3]-[4]. For removing the obstacles like resource complexity, the idea of the point of discretization for the process industry has been explained by Abdulmalek et al. (2006). This notion is based on the fact that in production flow route...
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...Courses Accelerated. Modular. Experiential Operations Management Course Planning, building and managing enterprise operations Course Methods: Experiential workshop (action learning course) Course Venue: Las Vegas, Nevada, USA Course Duration: 4 days Course Time: 9AM-4PM Course Dates: Management Training Courses Calendar Course Fees: $3,999 | Option 2: Operations Management Courses Online: $995 Why IIM?: CEO Club | Training Excellence | Client Testimonials Course Audience: * COO's Team: Operations Managers, Procurement Managers, Supply Chain Managers, Production Managers, Manufacturing Managers, Warehousing Managers, Inventory Managers, Quality Managers, R&D Managers, Innovation Managers, Project Managers, Entrepreneurs, and Operations Management Consultants. Course Objectives: * Provides an understanding of operations management framework * Offers experiential analysis to understand the challenges of COOs and Operations Managers * Provides an understanding of the functions and practices of production and operation managers * Training topics include supply chain management, research and development (R&D), manufacturing, project management and quality management * Provides insights on how to develop strategies, initiatives and programs to introduce and sustain competitive operations in organizations * Focuses on lean six sigma best practices, tools and models to develop and implement an effective...
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...seen in any of their Albany, Georgia; Pontiac, Michigan; and Hangzhou, China manufacturing plants. Their Chinese plant was set up as a joint venture between Riordan and small consortium of Chinese nationals. Capacity planning is a strategy that can be used to identify what is needed to produce what is being asked of the business in the way of demand for the goods and services. A capacity plan depends on accurate input and constructive feedback from the planners that supports the company’s long range strategy ("What Is Capacity Planning?", 2013). The market for fans and custom plastic parts will be affected by the economic conditions people are facing. Riordan has to take in account the economic impact from their customers and this is crucial in determining the future direction of the company. Riordan must avoid a decrease in the manufacturing of electric fans and focus on the capacity planning for the company. Riordan must first look at how to determine the capacity requirements and flexibility that they have in order to make in changes in capacity. Through the capacity planning they can accurately predict how much production they have and will have to produce to meet the demand for the product. Three ways that can help with capacity planning...
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...Running Head: Process Design for Riordan Manufacturing Process Design for Riordan Manufacturing: Inception to Production Planning Writer’s Name Course Name, Semester No, Class Level Supervisor Name September 23, 2009 Introduction The present paper discusses the proposal package for Riordan which handles each step of electric fans from inception to production. It includes the material requirement planning phase of fans being manufactured at the China Plant. There is further analysis of existing process for the production of the Riordan electric fans. It provides the basic outline for designing the new process to remove the bottleneck in the process to optimize it for meeting the demands of customer by supply-chain concepts. Production forecast for the Riordan electric fans is discussed along with implementation plan of Lean Production using Gantt Charts. Finally, cover letter describes the coordination of aggregate operations planning and suggested TQM process to define the strategic objective of the company. The MRP for the Manufacturing of the Riordan Electric Fans The China plant of Riordan Manufacturing is the production unit which applies material requirement planning to meet the time-phased requirement of material for assembled units or fan production operations. Raw materials are collected at receiving departments. These are processed to make it suitable for molding departments. The molded unit acts as input for trimming department...
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...BUILDING RESEARCH & INFORMATION (2003) 31(2), 119–133 Lean project management Glenn Ballard1,2 and Gregory A. Howell1 1 Lean Construction Institute, 4536 Fieldbrook Road, Oakland, CA 94619, USA 2 University of California at Berkeley, Berkeley, CA, USA E-mail: gballard@leanconstruction.org Projects are temporary production systems. When those systems are structured to deliver the product while maximizing value and minimizing waste, they are said to be ‘lean’ projects. Lean project management differs from traditional project management not only in the goals it pursues, but also in the structure of its phases, the relationship between phases and the participants in each phase. This paper presents a model of lean project management and contrasts lean and traditional approaches. Four tools or interventions are presented as illustrations of lean concepts in action. Keywords: construction management, Lean Project Delivery System (LPDS), lean project management, project management, value, waste Les projets sont des systemes de production temporaires. Lorsque ces systemes sont organise pour fournir le produit tout ` ` ´s en optimisant la valeur et en minimisant les gaspillages, on dit qu’il s’agit de projets au plus juste . La gestion de ce type de projet differe de celle des projets classiques non seulement au niveau des objectifs vise mais aussi a celui de la ` ´s ` structure des phases, des relations entre les phases et des participants a chaque phase. Cet article propose...
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...Process Design for Riordan Manufacturing The Riordan Manufacturing plant in Hangzhou, China operates its manufacturing unit to prepare the electric fan to provide the worldwide supply based on the production forecast sales extrapolated using the theory of moving averages for last three years. This paper includes an analysis of the material requirement planning, existing process design, application of supply-chain concepts including any available global opportunities. Additionally, this paper will include a production forecast and as well as an implementation plan for lean production and a just-in-time system to optimize the profit at Riordan and improve customer satisfaction with timely delivery of orders with appropriate inventory management system. Material Requirement Planning The material requirement planning of Riordan manufacturing is designed to supply the required material for creating the parts of electric fan in order to produce the components at each phase of assembly line production. The receiving department collects the raw material, which is processed in the molding department to make it suitable for generating parts of the fan after being polished and trimmed in the trimming department. These parts are further processed in the assembly department to make larger components such as fan blades or fan housings. The packaging departments puts each parts of the fan in right package with adequate labeling so that it can be delivered to distribution center...
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...Lean Project Management A research of Lean Production Delivery Systems on methods, processes and tools Zhiyuan Wang Author Note This report answers topic three This report was prepared for 49002 Project Management, taught by Elizabeth Bourke Abstract Current project management practices been found that have inherent difficulties in meeting increasingly stringent clients’ needs. However, it seems that the theories and principles of Lean Production Delivery Systems (LPDS) are the best approaches of all sorts of management theories. This assignment makes a brief Investigates and discusses of LPDS and analyses how to apply the principles, theories, processes and tools to current project management practices. This assignment concentrates on topic three and compares the difference between current and LPDS approaches in methods, processes and tools. Lean Project Management A research of Lean Production Delivery Systems on methods, processes and tools Background Before people name it Lean Production Delivery Systems1 (LPDS), many American experts call it TPS which is short for Toyota Production System (Womack et al., 1990). This production system been called as just-in-time production at the beginning state. It was created and developed by the founder of Toyota, in order to gain higher quality and lower cost, in the 1950 s. This production system became famous and been paid more attention by experts when Toyota made much profit during 1970s economic crisis while other...
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...rationale for lean. What features of assembly lines are common to lean systems? Features of assembly lines that are common to lean systems include: * Muda- waste and inefficiency * Pull system- replacing material or parts based on demand * Kanban- a manual system that signals the need for parts or materials * Heijunka- workload leveling * Kaizen- continuous improvement of the system * Jidoka- quality at the source 2.) (8) Contrast push and pull methods of moving goods and materials through production systems. In a push system work is pushed to the next station as it is completed. Releases are scheduled so output is determined by a set release rate. Since the releases are linked to orders (or forecasts), a push system is controlled by upstream information and is fundamentally make-to-order. In a pull system, a workstation pulls output from the preceding station as it is needed. Releases are authorized. That is, there is an internal signal based on system status that determines whether a release is allowed or not. 3.) (10) What are the benefits and risks of small lot sizes? Lot size directly affects inventory and scheduling. Benefits and risks of small lot sizes include: * Reduced inventory, lower carrying costs * Less space required to store inventory * Less rework if defects occur * Less inventory to “work off” before implementing product improvements * Increased visibility of problems * Increased production flexibility ...
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...LEAN SYSTEMS Reduction in inventory because of robots. Quick and faster. Change the layouts and set-ups. Is learning organization approach for designing supply chain system known as lean system. Lean systems are operation systems that maximize the value added by each of the companies activities by removing waste and delays from them. It is making more efficient, more quicker and faster( is lean system). Lean systems develop more efficient manufacturing operations. What is JIT just in time-that incorporates generic elements of lean system by cutting unnecessary capacity or inventory and removing non value added activities in operations. Eliminates waste or muda. 8 types of wastes : 1 over production, 2) in appropriate processing,3) waiting, 8) transportation( Excessive handling during transportation), 4) motion, 5) Inventory , 6) defects and 7) underutilization of employees. JIT system organizes the resources, information flow and decisions that enables firm to realize the benefits of JIT principle. Lean system leads to continuous improvement in quality and productivity. The Japanese term for this approach to process improvement is KAIZEN. Hides underlying problems with processes that produce service or product. Service processes improved : scheduling, billing, order taking, accounting, financial planning . SUPPLY CHAIN CONSIDERATIONS IN LEAN SYSTEMS : 2 characterstics of lean systems that are related to creating nad managing material flows in a supply chain ;...
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...Assembly Automation Emerald Article: Fundamental mindset that drives improvements towards lean production Yuji Yamamoto, Monica Bellgran Article information: To cite this document: Yuji Yamamoto, Monica Bellgran, (2010),"Fundamental mindset that drives improvements towards lean production", Assembly Automation, Vol. 30 Iss: 2 pp. 124 - 130 Permanent link to this document: http://dx.doi.org/10.1108/01445151011029754 Downloaded on: 01-12-2012 References: This document contains references to 13 other documents Citations: This document has been cited by 4 other documents To copy this document: permissions@emeraldinsight.com Access to this document was granted through an Emerald subscription provided by JOMO KENYATTA UNIVERSITY OF AGRICULTURE A TECHNOLOGY For Authors: If you would like to write for this, or any other Emerald publication, then please use our Emerald for Authors service. Information about how to choose which publication to write for and submission guidelines are available for all. Please visit www.emeraldinsight.com/authors for more information. About Emerald www.emeraldinsight.com With over forty years' experience, Emerald Group Publishing is a leading independent publisher of global research with impact in business, society, public policy and education. In total, Emerald publishes over 275 journals and more than 130 book series, as well as an extensive range of online products and services. Emerald is both COUNTER 3 and TRANSFER compliant. The organization is a partner...
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...the lean and typical production process and how they both vary differently. Lastly, give Dr. White some information and a proposal on how to prepare for a decreased budget. MANAGING COST Introduction In our ever changing business world, each organization must find ways to make tight budgets work. Management are always facing ways to increase the bottom line and find innovated ways to meet budget guidelines. Dr. White is faced with the decision to decrease the budget by $94,000. Recommendation will be listed below as to how Dr. White might proceed to cut the organization’s budget. Managerial Accounting Many organizations have managers that run the day to day operation. In order for the company to be successful in its practices there must be accountability. One way to hold accountability is to have accounting. Managerial accounting is an effective way to provide data to the managers that oversees the companies productivity. Many managers provide planning, control operation, and find ways to keep overhead at a minimum. Techniques can be used in the planning process as well, and that is to also help control the budgeting. It is very vital to have the data delivered for the cost accounting to make sure that it is accurate and suitable for the management process. The data analysis can be used in many different aspects, and that may vary; some of those ways may be direct costing, investment budgeting, discrepancy of the analysis and much more. When it comes to the lean production...
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...Research on Lean Project Management Summary This report explains theories and assumptions of current project management methods, and compares it to the Lean Production Delivery System (LPDS) by showing advantages and disadvantages of each method. This report also includes how the LPDS is more efficient than other methods by eliminating wastes and save cost and duration. Introduction: Client needs nowadays are getting more stylish due to the continuous new challenges in the environment, economy, technology and society for the necessity of creating or upgrading new projects. Meeting these requirements involves changing old methods in managing projects into new ones which are more essential to meet the needs of the market. Moreover, new concepts have been considered in addition for the time, cost and quality to guaranty the success of a project. Many new concepts could be presented for production management, but the Lean Production Delivery System (LPDS) is one of the most successful practices concerning the development of project management. For this matter, this report will include an investigation and discussion comparing the advantages and disadvantages of current project management methods and Lean Production Delivery Systems (LPDS). Current project management methods, Advantages and Disadvantages: As described in the text, ―Project Management is the application of knowledge, skills...
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...processes to cope with the ever growing challenges. To be more efficient is the only way to stay and earn profit in a global market. Industries are giving lot of attention to Lean manufacturing. Several industries are struggling to be world class. Principal adoption of lean manufacturing is still found to be complex. Lean Manufacturing is a set of techniques, which have developed gradually over a long period and are based on various minor to major breakthroughs that help in reducing cost and hence increase productivity. Lean is a philosophy of manufacturing that incorporates a collection of principles, tools and techniques into the business processes to optimize time, productivity, HR, and assets, while improving the quality level of products and services to their customers. LEAN MANUFACTURING Lean manufacturing is defined as to produce same and more than the mass production using less effort, lesser space, without any new inventory, better quality and lesser defects. Lean manufacturing improves operating performance by focusing on the quick and uninterrupted flow of products and materials through the value stream. To achieve this, the various forms of manufacturing waste must be identified and eliminated. Waste can include any activity, step or process that does not add value for the customer. If we try to define Lean Then we can say “A systematic...
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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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