The Aspects Of Lean Manufacturing Planning And Execution

Reliable quality and rapid delivery are the two key customer expectations that modern business organizations strive to fulfil for ensuring their growth and success. For this the companies need to work towards minimizing the cycle time for various business processes as otherwise they run the risk of losing customers. In this context, lean systems offer a reliable solution for organizations looking to attain and maintain optimal operational efficiency and highest customer satisfaction levels. However, in order to get the best results from such systems, the top lean consulting firm in India advise their clients to gain an in-depth understanding about their various key aspects.

Lean Manufacturing Implementation

In order to get the best results, it is important for business organizations to first garner firm support of top management for the initiative. This requires making it clear to the management that several processes might need to be changed. The best way to convince the management of the effectiveness and benefits of implementing a lean system is by carefully planning and   test implementing the system for a single product line. Once the management acknowledges the benefits of the system, it can be expanded for a broad-scale execution.

Apart from gaining support from the top management, it is also important to prepare and involve the mid and junior level employees for the change. For this the organizations need to identify and executive, who can be trusted to promote lean program and also become engaged in its planning. The organization should also make sure to educate employees across all levels about the new systems to be implemented. It is also important to lay out the comprehensive designs for the new or modified processes besides developing a plan to test run the system in a single operational area.

The organizations also need to set quantified goals that can help them access the level of improvement attained with respect to various aspects of performance. Once the test run has been successfully approved, they should design plans for implementing the system across the organization in multiple phases. However, even before the initiation of the first phase, a full confirmation should be obtained from the management for the same. The implementation of each phase should be done in accordance with well planned time-tables to minimize any disruptions in the normal business operations.

Measuring The Performance Of  Lean Manufacturing

As per the leading lean manufacturing consultants India, just implementing the lean system is not enough. Organizations need to make sure that they have a well-rounded set of metrics in place to measure the performance of lean manufacturing systems. This might involve performing regular assessments to ensure the following.

• Elimination of delays in information transmission due to smoothening of workflow processes.

• Reduction in useless steps through physical reorganization

• Proper recording of paper and electronic files to minimize confusion

• Balancing of schedules for better utilization of time and enhanced productivity

• Appropriate grouping of similar tasks or those that need to be performed along the same route

By monitoring these aspects, business organizations can gain a better understanding of the steps they need to take to further enhance the benefits and advantages of implementing lean system.

5 Most Essential Lean Construction Tools That Are Must To Use

Manufacturing Consultants in India are in high demand as the Construction projects can save billions of Rupees by systematically optimizing processes using modern tools and techniques. Capabilities of the workforce can be enriched manifold by understanding the process of providing value to each customer at the same time achieving the Zero Defect.

One of the most known way of contributing to the increase in productivity is to implement Lean Construction. Top Lean Consulting Firms in India use various tools and techniques to provide basic knowledge and benefits of Lean Construction. Some of the tools are as follows:

1. Waste Elimination

The foremost tool or technique to achieve maximum productivity is to eliminate non-value adding activities in Construction such as Overproduction, Transportation, Waiting, Rework, Inventory etc. Studies have shown that Waiting, Rework and Over-Processing account for almost 73% of the waste in construction. Identifying all the reasons that are leading up to these waste can go a long way in achieving the Zero Defect Goal.

2. Value Stream Mapping

The set of methods laid down to visually display the flow of information and materials all through the production process is value stream mapping. The main objective is to identify non-value-added activities and value-added activities. In other words, it is an account of real world process rather than the bookish process of how the things are supposed to happen in the ideal scenario. This opens up opportunities for improvement as the various lags can be identified and fixed with new knowledge that has been acquired through this process.

3. Fail Safe For Quality

This is the quality first approach and has the capability to save upto 29% of the cost overruns. Fail safe for quality means to remain constantly focused on safety and quality from the beginning till the end. Throughout the process the potential areas of quality improvements are identified and implemented on the go in order to improve the end result. This proactive approach is similar to Poka-Yoke in the lean production system.

4. The Last Planner System

During the life of the project, different levels of planning are required at different time by different people. The entire planning process, however diversified, focuses on particular set of objectives. The tag of “The Last Planner” is being assigned to the individual person or a group who creates the projects or the assignments. The specific objectives govern the entire planning process and becomes a guiding light for all the stakeholders involved.

5. Total Flow Management

Construction are big projects that involve large number of stakeholders as mentioned above. These stakeholders are involved right from the initial stage of idea generation till the time building is being handed-over to the clients. In order to ensure that there is no confusion and all the planning is done in the right way it is very important to have a  properly defined flow. This is also known as Standard Operating Procedure (SOP). It must be clearly put forth in front of all and there should be no confusion in any context. The SOP if followed during life cycle of all the projects, not only it would become a standard but would also create a level of understanding amongst all regarding their respective work thereby eliminating the chances of mistake.

The Different Features Of Lean Manufacturing For Better Business Growth

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.

The Different Features Of Lean Manufacturing For Better Business Growth