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Lean Manufacturing in a Continuous Process G Mérian 5/3/04. A lean approach in a continuous process. A Flooring company For Residential & Commercial North America – West & East Europe Mainly cushion floor 2 0 plants ; 7000 people. A typical line : 400 meters long
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Lean Manufacturing in a Continuous Process G Mérian 5/3/04
A Flooring company • For Residential & Commercial • North America – West & East Europe • Mainly cushion floor • 20 plants ; 7000 people
A typical line : 400 meters long From a glass fibre film to many 25 meters Finished G. rolls
Some consequences : • No intermediate stocks • No stream value analysis in the plant • No Hoshin workshop • No possibility to double an intermediate capacity
But the same questions : • Is my process and its steps : • Valuable => (wastes) • Available => (TPM) • Flexible => (Smed) • Capable => (SPC) • => Almost the same tools ?
Some specifics : • Tracking Board, is a way to create tension in the line ? • GAP (line or part of it ?) • People have time (tension ?) • Batch sizes (when you run, keep running….)
Leaning towards Lean Manufacturing even in a Continuous process is a Continuous Improvement Program