Lean manufacturing is a team based approach to achieving manufacturing excellence. At its core, lean manufacturing is achieved when all waste and non-value added steps have been eliminated. While this seems simple on the surface, the reality is that factors such as the shop floor footprint can have a profound impact on whether or not there are wasted movements or bottlenecks in the manufacturing process. In my experience, only those project that include front-line supervisors and key managers in the change process have had success in sustaining continued refinement in lean operations. This is because they are more committed when included in the change process.
One benefit to reducing waste will be the reduction in lead time necessary to fulfill orders. This allows your company to be more agile in responding to customer's needs without adding cost. This business model will also have a dramatic positive impact on your cash flow by eliminating costly rework and reducing materials holding costs.
When we talk about eliminating waste to achieve a lean manufacturing environment, we specifically want to focus on three areas:
In today's business environment, companies are turning to reducing their workforce to improve their bottom line. While some reduction in this area is probably warranted, best in class companies recognize that letting go of key staff without implementing a lean manufacturing initiative can harm them in the long run. After all, who knows your production process better: the person who has been there for a while, or the person you are about to hire?
The truth is, most manufacturing costs are found in materials, purchased parts, work-in-process inventory, and finished goods. If you make your products to order, you will improve your bottom line. Where possible, implementing and integrated supply chain will further improve your lean manufacturing intiative and your ability to control costs.
Taking on the task of evaluating your production systems can be disruptive and might seem like a daunting task, but companies that do it have realized significant improvement in staff morale, cash flow, and order response time. TML Business Services has been helping companies achieve lean manufacturing excellence since 1998 and we can help you too! Call us at (215) 280-9922, or Email TML today to discuss your unique needs.