Lean Manufacturing Demystified

1. LEAN MANUFACTURING DEMYSTIFIED MACHINE DOWNTIME TRACKING & OEE MANAGEMENT

2. Lean Manufacturing is one of the most revered principles of manufacturing industry which most of the managers would most sincerely want to implement at their establishments as it has the potential to bring the most fruitful results in a production house. However, as far as understanding of the concept is considered, some people understand lean manufacturing as a way to eliminate waste in the production line, whereas some others consider lean manufacturing as a way to attain perfection in production economically by organizing the workplace and working methodologies in an orderly manner. However, the fact is that lean manufacturing is all this but a lot more too.

3. LEAN MANUFACTURING- ADDING VALUE TO THE PROCESS AND PRODUCT TOGETHER Lean manufacturing is a systematic approach which aims at adding value to not only the product when it reaches the end customer but also to the whole process of manufacturing. Lean manufacturing strives to attain order, standardization, discipline and respect at the workplace while achieving all these goals it also aims to maintain safety in all aspects of production and for this it uses various tools like TPM, OEE, 5S techniques, etc. so that any waste in the process can be eliminated and profits can be maximized from the process itself.

4. Simply put lean manufacturing is a process which aims at producing goods in shorter lead time continuously with high quality and precision while also adding value to the product. This process aims at maximizing profit of the producer not by increasing the price of the commodity but by eliminating waste in the process which was eating up the profit and hence the customer gets better quality product at the same pricing. So not going by the complicated technical definitions of the industry specialists and simply putting lean manufacturing tries to do the following:

5. REDUCE ALL KIND OF WASTE IN THE MANUFACTURING PROCESSES This is one of the most important part of being lean. If the process is full of unnecessary baggage how can it be lean? And that’s why lean manufacturing focuses on identifying waste on all aspects of production.

6. • Unnecessary tools and equipment used in the process • Unnecessary manpower used in the processes or the processes that are using more than required manpower or keeping them idle • Unnecessary processes that are using up time of other workers or equipment or keeping them idle • Identifies unnecessary delays caused in the production and focuses on the reason for complete resolution • Unnecessary waste in production of bad quality products

7. • Identification of waste of product, labor, time, money, management and resources in producing those goods identifying the reasons and rectifying them. • Identification of unnecessary inventory load on the production house • Identification of actual demand and supply cycle and only producing what is required rather than first producing and then creating an artificial demand

8. ADD VALUE TO THE PRODUCT BY INVESTING IN MAKING IT BETTER HOLISTICALLY Lean manufacturing lays great emphasis on adding value to the product which can be transferred directly from the raw material to the end user. Value can be added to the product by producing what is required in the exact quantity it is required and delivering it at the required time while maintaining great quality in it. Lean manufacturing envisions if the whole cycle is synchronized then perfect quality product can be delivered in the exact cost as earlier but with higher profit margin saved from eliminating waste and inventory costs. Hence, in this way everyone will be a winner from producer to the consumer.

9. MAKE THE WORKPLACE MORE ORGANIZED AND SAFE FOR WORKING Cleanliness at workplace is one of the vital ingredients to ensure safety. When the surrounding is clean and clear and free of obstructions there are less chances of accidents happening and a safe environment invokes a feeling of positivity in the minds of the workforce. The workforce is trained and inspired to lay more emphasis on cleanliness and orderliness of their workplace in this way problems can be quickly detected and dealt with easily and as a result downtimes can also be reduced.

10. REDUCE UNPLANNED DOWNTIME AND FREQUENT BREAKDOWNS Applying overall equipment effectiveness techniques to detect problems in real time is a great way to reduce unplanned downtimes and lean manufacturing tries to do that precisely. It aims at carefully studying the reasons of frequent downtimes and then eliminates the causes sequentially and hence great Overall Equipment Effectiveness Score can be achieved which results in lower unplanned downtime and higher productivity. 

11. Lean manufacturing is a broader concept with simple principle to make the process efficient and reduce the unnecessary things from the whole cycle so that the process can be streamlined. It is a principal which makes companies become more consumer friendly by giving higher quality products at the same price and that too much faster. https://www.downtimecollectionsolutions.com