LEAN MANUFACTURING CONCEPT EXPLAINED by BLR1UU

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									          L E AN M ANUFAC TURING
           CO NCE P T E XPLAINE D

      LEAN MANUFACTURING IS THE SYSTEM WHERE WASTES ARE
   CONTINUOUSLY IDENTIFIED AND REMOVED IN ORDER TO CREATE
                                       VALUE




SUNDAY, AUGUST 06, 2006

Lean manufacturing concepts in communication 3 –
Longer channel lengths
We have been talking about the possibility of using lean manufacturing concepts
to improve your communication process. We have already talked about two
wastes occur in traditional communication channel, which are overloading and
waiting. Today we will concentrate on the third. This is the long length of the
communication channel. This is the equivalent of the higher transportation in
lean manufacturing.


In most of the organizations one piece of information will be passed through
many people without any processing of information. For an example a manager
to his assistant and from the assistant to the clerk who is actually use this
information in his work.


Every additional point in the communication channel adds unnecessary delays
and creates the possibility of making errors. People don’t understand the fact that
large amounts of information is passed through them because this is done mainly
electronically. But this adds up to the lead time of the manufacturing since in
every moment that information is waiting for the processing is adding up to the
lead time. This also wastes people’s time since they have to process unnecessary
information.


You will find this problem of information flow within your organization. You will
also find problems like this between your organization and customers and
suppliers. Think with lean manufacturing cap on. Draw a communication
diagram and map your information channels. Find out unnecessary mid points
and get read of them. Make your communication channels short and focused.
POSTED BY AZA BADURDEEN AT 12:42 AM 0 COMMENTS




SUNDAY, JULY 30, 2006

Lean manufacturing: the buyer’s responsibility
In today’s world many of the brand owners does not do manufacturing them
selves. They serve their retails markets and they let third parties to do the
manufacturing for them. Large organizations have very organized ways of getting
this done. They have manufacturers producing for them all over the world.
Products are consolidated at central locations and distributed to the relevant
countries and destinations.


This is one of the ways they keep their costs down and keep to their core
competencies. But as a manufacturer for these large organizations, they have few
problems to face, especially if they are looking to apply lean manufacturing. Lean
manufacturing is very much dependent on the response of the buyer or the
customer to manufacture. The pull manufacturing strategy is completely
dependent on this response. So to manufacturer to be lean, they have to get good
support from their buyers. But there is a problem.


End customers are too far away in the supply chain. So it will take fair amount of
time to get the real end customer feedback in the process of manufacturing. So
the manufacturer will have to work on predictions to fulfill the requirements.
This means that they can not be truly become lean.
So what is the solution for this problem? Answer is simple. It is to get read of all
the intermediates from the information flow. Is it possible? Yes this is possible. In
fact many large organizations are doing this. Simply they allow their
manufacturers to see their sales statistics and manufacturers are empowered to
manufacture according to the requirements generated by sales. This is the
information age without any doubt. It will take only few seconds to transmit this
information form the retail shop to the manufacturer. So any manufacturing
system can become a lean manufacturing system.


Any brand owner will love just to sit back and think how to improve their sales
without thinking about manufacturing process.
POSTED BY AZA BADURDEEN AT 5:50 AM 0 COMMENTS




TUESDAY, JULY 25, 2006

Interesting lean manufacturing technique: Ask Why 5
times
I found an interesting tool used by Toyota in its efforts of making the waste free
manufacturing facility. Lean manufacturers always believe problems are the
sources for improvement. Therefore every problem is an opportunity for
improvement. So how lean manufacturing use problems to their advantage.
Toyota’s website gives us a simple tool to use.


According to Toyota’s Taiichi Ohno, when you have a problem you should look at
the problem and ask the question why five times. For an example lets say you
have number of quality defects in transportation. So you attend the problem by
asking why you get quality defects while you transport. When you get the answer
to that question, most probably that answer itself will reveal a problem in the
system. Do this over and over again until you get to the root cause of the problem.
Then get read of this cause. Your problem will be solved automatically.


What is the important concept behind this? That is finding the root cause and
treating it. Important message is not to treat symptoms, but to treat causes of the
problems. This is the lean way of thinking.
POSTED BY AZA BADURDEEN AT 5:22 AM 0 COMMENTS




SATURDAY, JULY 15, 2006

Lean concepts in communication 2 – Waiting
Lean manufacturing has its strength in its concepts. As I have been talking
throughout my blog lean concepts can be applied to communication. So we will
look at the second waste that can occur in the process of communication. This is
waiting for information


In manufacturing context waiting refers to the idle workplaces which are waiting
to do their jobs. But in the context of communication this is not just wasting of
time and resources of one process. Waiting for information can cause chain effect
in the process and can stop your full process. Every small bit of information is
very important to the process. It is not enough to be 90%. You should have
correct and complete information to carryout your work.


Every piece information must be there to be processed when they are required.
Having them in very early stage will mean only little since they are not being
processed. This can cause problems since this piece of data might not be up to
date. On the other hand waiting for information can virtually stop the
functionality of the organization. So Just In Time is very important here. Lean
manufacturing concepts should be applied organization wide in order to create
the perfect lean organization.
POSTED BY AZA BADURDEEN AT 4:42 AM 0 COMMENTS




WEDNESDAY, JULY 05, 2006

Lean manufacturing concepts in day to day life – 2.2K Vs
2K2
One of the main principles of lean manufacturing is mistake proofing. The system
is designed in a way that mistakes will be avoided by the system. This is
commonly known as Poka Yoke in lean manufacturing.


I found one interesting application of this concept in an electronic publication.
Resistance is normally measured in Ohms or in kilo Ohms. It is mentioned as
2.2k normally. But this leads to many problems because when it comes to
printing there is a probability of not printing the decimal point properly. Then
this will be interpreted as 22k instead of 2.2k. Needless to say the problem this
can create.


But if it is mentioned as 2k2 nobody will get confused and it is not difficult to
understand. This is a very simple technique used to achieve excellent results. This
is exactly the concept of Pokayoke. Lean thinking is based on simple changes to
achieve the objectives of lean.
POSTED BY AZA BADURDEEN AT 8:29 AM 0 COMMENTS




TUESDAY, JULY 04, 2006

Lean concepts in communication 1 – Overloading of
information
In a previous post I talked about using lean manufacturing concepts in
communication and information handling. Today we will look at the lean concept
of over production in the context of communication.


The term overproduction can be defined as the overloading of information in the
context of information. Unnecessary information when they are not required
creates overloading of information. Unnecessary information creates confusion.
This is one of the main courses to problems in processes.


Only the required information must come into the system when they are
required. This information should be well formatted so that it will be easy to
capture and analyze. Every information processing point must be well defined so
that everyone in the communication process will know exactly what information
to collect and what to give out. No information should be passed to the next
process until that process requires it. Also it is very important to give them the
required information in a standard format so that they will be able to use it easily.


Lean communication is a very essential aspect of any lean manufacturing
organization.
POSTED BY AZA BADURDEEN AT 9:11 AM 0 COMMENTS




MONDAY, JULY 03, 2006

Is Your CC list long – you are not a lean manufacturer
Emails and other forms of e communication is widely used allover the world. I am
sure you do use emails everyday. I found an interesting fact sometime back when
I studied few suppliers for an organization. Some emails contained many, many
addresses in the CC list of the email. Then I found out these organizations are not
performing well and associated with many problems like delays and quality
problems.


Lean manufacturing depends on perfection. Every activity is well defined. Not
only the work, but the way it has to be carried out is defined. Every responsibility
is well identified. Therefore if you are a lean manufacturer you will ideally see
only one address in your email under TO field and none in the CC list. Reason is
you will be doing something well defined and you have the full responsibility of
that activity. There is no need you to tell someone else what you are doing, when
he is not directly involved in your activity. Long CC lists creates confusion.
Responsibility is not focused and it is scattered. This will create a process where
everyone is overloaded with information yet no one is actually responsible for the
actions they take. Obviously this can not be a lean manufacturing system.

								
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