There
has been a significant rise in the popularity of implementing lean
manufacturing plans and strategies amongst businesses of all sizes. The concept
has been around since the 1980’s, when renowned automobile manufacturer Toyota
first implemented the technique and attained phenomenal success. However, it
has only been over the past several years that business organizations across
the globe have become serious about using the technique. However, before hiring
the services of lean manufacturing
consultants in India, it is important for the business organizations to
thoroughly understand this concept and its various aspects. This can help them
maximize the benefits to be obtained by the implementation of this technique.
What Is Lean Manufacturing?
Lean
manufacturing can be compared to a healthy diet plan that aims to make an
organization faster, fitter and more competitive. It focuses on tightening
processes, minimizing waste and steering the bottom line towards robustness. In
other words, implementing the principles of lean manufacturing can help a
business to turn into a high performer within its niche and thus naturally enhance
its profit margins. This is ensured by eliminating wastage which might be in
prevalent in various forms ranging from over-extended equipment setup to
surplus inventory. It addition, the technique also proves beneficial in
creating a flexible manufacturing process that not only helps to streamline but
also speed up the timely delivery and product flow for the business.
Various Phases Of Lean
Manufacturing
Implementing
lean manufacturing strategies is carried out in multiple phases to ensure
greater efficiency and self-sustaining continuous improvement. These phases are
explained in brief as follows.
Obtain A Clear Understanding
Of Manufacturing Process
The
first phase of lean methodology comprises of attaining a clear understanding of
how a business creates its products. The lean manufacturing consultants analyze
the existing manufacturing practices followed by the business and then compare
them with truly lean ones. This helps them to identify the gaps between the two
types of process and development of an effective strategy to eliminate the
same. This analysis is performed by monitoring scheduling, inventory
management, customer service and communications and quality. In addition the
consultants might also choose to interview key personnel, reviewing procedures
and closely observing the various business processes.
Identifying Avoidable
Expenses
Having
understood the manufacturing process, the professionals from the top lean consulting
firms in India, move on to identifying avoidable expenses within the
organization. This is done by analysing issues such as unnecessary human
movement, non-value-added conveyance of products, over production, excess
inventory, wastage of space, over-processing needless waiting and improper
utilization of talent. The consultants suggest the best ways to take corrective
action for minimizing these wasteful aspects of business operation, without
affecting the business objectives or creating stressful and depressing work
environment.
Enhancing The Efficiency
Of Operations By Minimizing Errors
In
the third phase, the consultants focus on reducing the variability in business
processes by improving flow and quality with special focus on enhancing
efficiency and minimizing errors. This is ensured by optimizing the pace of
work, point-of-use fabrication, overall productive maintenance practices,
poke-yoke, and using a wide range of statistical lean tools as applicable for
the organization.
Creating And Executing A
Demand-Based Pull System
The
fourth phase focuses on reducing the overall inventory, order turnaround time
and works in progress. This is ensured by calculating, creating and executing a
demand-based pull system based on various lean techniques and methodologies.
The objective of this phase is to help improve lead time for the business and reduce
inventories.
Establishing Continued
Improvement Procedure
The
final phase focuses on establishing a continued improvement procedure for the
business. For this the consultants also provide comprehensive on-site training to
all stakeholders to educate them about the use of simulations and creating
infrastructure to help the organizations achieve operational excellence.
