The Different Features Of Lean Manufacturing For Better Business Growth

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.