What you should know about implementing lean manufacturing efficiently

What you should know about implementing lean manufacturing efficiently

The process of implementing lean manufacturing efficiently is much like implementing any new procedure in business in that it is usually met with unique challenges. There is no step-by-step guide to implementing procedures into your usually business operations. There are however suggested methods for doing so. Generally, the implementation process begins with management. It is the management team that decides that the implementation of a new process is necessary and it should be that management team that decides exactly how the implementation should take place.

Many times this process of implementing lean manufacturing is discussed in a committee and a proposal is voted on. Once every one agrees that the implementation should proceed forth according to their plan the implementation is put into action. Managers are responsible for training and instructing supervisors while supervisors are then responsible for training their employees. Quality control is vital in any implementation process. The quality control and in this case a team that is specifically trained to oversee the productiveness and effectiveness of the new implementation, is responsible for then reporting back to management.

After some time has been given to see how the implementation is really affecting the business and the workers, some changes can be made and new aspects of the implementation can be emphasized as management and the quality control team find is appropriate. The implementation process does not happen overnight. The planning process is extensive and many times the implementation plan will need to be changed and parts of the plan may be eliminated all together. Change is necessary in order to maintain a competitive edge in the manufacturing industry, as with any other industry.

When implementing lean manufacturing efficiently, there are some specifics that will need to be addressed. The first and most important principle of lean manufacturing that should always be kept at the front of the minds of the management team is that lean manufacturing has a goal of reducing costs through eliminating waste.

Principles of eliminating waste include, but are not limited to, the following:

* Just-in-time - A product is only made when the customer directly requests the product. This way supply always meets demand and there is no need to acquire the costs associated with inventory and other product holding costs.

* Zero defects - In lean manufacturing perfecting the production process so that there are no defects is a vital part of the implementation process. Special emphasis needs to be placed on making sure that a product can be made exactly to specifications every time.

* Flexibility - It may be easy enough to perfect one product, but many manufacturers produce a number of different products or specialize in custom work at the request of the customer. This is why flexibility is an important part of the overall lean manufacturing vision. You must discuss how you will implement production of a diverse product at low production volumes while still eliminating waste and being profitable.

* Autonomation - In the lean manufacturing program there must be a system in place that will allow for the stop and repair of production in the case that a defective product is being made. In other words, check points in the production process should be controlled to the point that if there are glitches in the system they can be found and fixed with minimal interruption to the process of production.

* Relationships with vendors - Very few businesses make their products from materials that were grown or otherwise harvested on the same site of production. Most manufacturers have suppliers. These suppliers play a vital role in lean manufacturing. When you have a good relationship with your suppliers there are not as many variables when it comes to discussing business arrangements, knowing when to expect deliveries, etc. Having a strong relationship with a supplier eliminates wasted time in this part of the manufacturing process.