Lean Manufacturing Concepts Discussion

[sudarsan]

i am sudarsan a student. i am interested in Lean Concepts.i was thinking on starting a new thread on discussion about Lean thinking . Everyone can give their views about Lean thinking. since most of them are in industries it would be great if they come out real practical example.i would like to go by this way

1. Discussion on Topic and concepts of Lean Manufacturing. The discussion can be weekly or it can continue till topic dies out.

2. i will be posting Book overviews or just the glimpses on each topic of discussion . As a student , i think i can only do that now.i will refer some books and will discuss about that in the Forum.

3.Member can suggest Topic of discussion and we can discuss on that.

4. We can even discuss articles ,white papers which we find interesting to discuss.

i am starting this thread to learn lean from industrial experts .Hope i will get real support from all the members.

Thanks

sudarsan

[triner]

I posted a message in book forum with a similar idea, but perhaps this may be the better place for it since most of the books I have read are related to lean also.

I look forward to some interesting discussion.

[sudarsan]

i would like to Start a discussion on how lean concept came into this world of manufacturing.Interested members can give their replies on this topic. I would appreciate if members can post good articles on this topic and discussion.

Looking forward for more replies.


Thank you

sudarsan

[Randy]

It came into being because of the need to be more profitable, everything else is secondary.

[sudarsan]

i would like to give my view on how lean manufacturing came to this world.When i was searching for some details about this in google , i came across a article giving some history of Lean Manufacturing which i would like to share with you People.After reading that articles, i would say best way to understand Lean manufacturing is to start with its roots in the Toyota Production System. Toyota started by following the basic principles set out by Henry Ford with the moving assembly line.

Henry Ford preached the importance of creating continuous material flow, standardizing processes, and eliminating waste. When Ford started producing millions of black Model-Ts which evolved to be a wasteful Batch production, they gave a call for eliminating the waste in production which ultimately turned out to be foundation or basic of lean thinking. Since the Toyota did not have luxury space, money and large production system like ford they developed a flexible system to respond customer demand .This turned out to be very effective one which is so called Toyota production system.

[Randy]

Instead of wasting your time discussing the "how" why don't you try to understand the "why"?

[asutherland]

There are a lot of threads here on lean thinking . . . and even some good ones on lean doing.

Is it possible to carry lean too far?

Hummm, dont know . . . for me, I am so lean, I swallow a wad of tissue paper about a half hour before potty . . . so I don't have to waste time to wipe.

[sudarsan]

Hi Randy,

Thanks for the reply. yes as you said WHY ?.Here are few reasons why lean was implemented.

1.Reduce Lead time.
2.Increse the productivity.
3.Reduce WIP inventory.
4.Improve the Quality.
5.Improve Space utilization.
6.Minimize Waste

The above can be operational improvements.

some of the other reasons may be

1.Reduction in order Processing errors.
2.Reduction of Paper work in office areas.
3.Streamlining of customer service functions so that customers are no longer placed on hold.

These can be administrative improvements.

so these are few reasons why lean was implemented .

sudarsan