Companies tend to think that lean manufacturing is a
complicated, convoluted and drawn-out process. Granted, the calculations
involved in determining production throughput and manufacturing capacity can be
quite an involved and laborious affair. However, lean manufacturing itself is a
fairly easy concept to grasp. In fact, the best example of lean manufacturing can
be found right in your own kitchen.
Kitchens incorporates a number of lean principles and concepts. First, your work space is functional and easily navigable. It’s easy for you to move from one task to the next with minimal time wasted. Second, all of your raw materials are found within your work space: You spend very little time looking or searching for what you need when you need it. Third, all of your tools and equipment are readily available: Once you enter your kitchen, you shouldn’t have to leave until you’ve finished your task. Most importantly, your tools and equipment are yours and yours alone: You don't share anything and that guarantees you minimize downtime.
I use this aforementioned example all the time when trying to simplify continuous improvement in manufacturing. I want my customers to focus on simple strategies, ones that don't require too much analysis and review. In essence, if it makes sense, then move forward.
While I am not certified in Six Sigma, I still rely upon several Six Sigma calculations, processes and strategies when working with manufacturers. However, my approach is to simplify lean manufacturing so that any manufacturer can apply simple and straightforward concepts to reduce downtime and eliminate work stoppages.
Simplifying Lean Manufacturing: Work Cell Output, Cycle Time Variances & Production Volumes
Companies are often intimidated by lean concepts because they believe these concepts are only applicable and beneficial in high production volume manufacturing environments. The idea is that companies must manufacture thousands upon thousands of units in order to benefit from process improvements. However, this simply isn’t the case.
Lean concepts are important no matter what your company is manufacturing and no matter how much it manufactures. Their basic premise is to improve output by identifying the root causes of downtime and process deficiencies. If you eliminate these root causes, then you'll improve your output. This applies to everything within your company - from your supply chain strategies, to your operations, sales, customer service, marketing, engineering, manufacturing, invoicing, shipping and ultimately, your after-sales service and support.
Granted, there are some incredibly complex lean calculations, matrices, distribution models, variance analyses and theorems that can all but drive someone completely insane. While they have a role in certain applications, understanding everything about them isn’t a prerequisite to benefiting from lean concepts. All it takes is your willingness to simplify how work is done on your shop floor.
You can read more about simplifying these concepts by reading one of the following articles:
Manufacturing Work Cell Optimization: Design, Layout and Analysis
Manufacturing Cycle Times: Use Pareto Charts to Graph Lost Time
Cycle Time Tracking & Variance Analysis in Excel for Small Manufacturers
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