world- class companies
DESCRIPTION
This is a discussion about world-class companies.TRANSCRIPT
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WORLD- CLASS COMPANIES
AND LEAN MANUFACTURING
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WHAT IS A WORLD-CLASS COMPANY?
Features:
World-class companies must maintain strategic agility and
be able to turn on a dime.
World-class companies motivate and treat employees like
appreciating assets.
A world-class company profitably meets the needs of its
customers.
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WHAT IS A WORLD -CLASS COMPANY?
Features:The philosophy of customer satisfaction permeates
the world-class firm.
Manufacturing firms that achieve world-class status
do so by following a philosophy of lean-manufacturing.
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LEAN MANUFACTURING- This manufacturing approach is in direct
opposition to Traditional Manufacturing.
- Evolved from the Toyota Production System (TPS), which is based in Just-in-Time (JIT) Production Model.
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LEAN MANUFACTURING- Goal: Improved efficiency and effectiveness in
every area, including:
Product Design
Supplier Interaction
Factory Operations
Employee Management
Customer Relations
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PRINCIPLES CHARACTERIZING
LEAN MANUFACTURINGPULL PROCESSING.
- involves pulling products from the consumer end (demand), rather than pushing them from the production end (supply)
PERFECT QUALITY.
- success of the pull processing model requires zero defects in RM, WIP and FG inventory; quality is a basis on which world-class manufacturers compete
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PRINCIPLES CHARACTERIZING
LEAN MANUFACTURINGWASTE MINIMIZATION
- all activities that do not add value and maximize the use of scarce resources must be eliminated
Lean Manufacturing seeks to minimize: Overproduction of products
Transportation of products
Bottlenecks of products Idle workers
Inefficient motion of workers
Islands of technology Production defects Safety hazards
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PRINCIPLES CHARACTERIZING
LEAN MANUFACTURINGINVENTORY REDUCTION.
- hallmark of lean manufacturing
- lean firms have only a few days or sometimes even a few hours of inventory on hand
3 Common Problems (Why Inventory Reduction is Important)
1. Inventories cost money.
2. Inventories camouflage production problems.
3. Willingness to maintain inventories can precipitate overproduction.
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PRINCIPLES CHARACTERIZING
LEAN MANUFACTURINGPRODUCTION FLEXIBILITY.
- lean companies strive to reduce setup time to a minimum, which allows them to produce a greater diversity of products quickly, without sacrificing efficiency at lower volumes of production
ESTABLISHED SUPPLIER RELATIONS.- a lean manufacturing firm must have established and
cooperative relationships with vendors
TEAM ATTITUDE.- lean requires a constant state of quality control along with
the authority to take immediate actions
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TECHNIQUES AND TECHNOLOGIES
THAT PROMOTE LEAN
MANUFACTURING
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MANUFACTURING FLEXIBILITY- achieved by Lean Companies to meet the
challenges of modern consumerism
PHYSICAL REORGANIZATION OF THE PRODUCTION FACILITIES
The flexible production system is organized into a smooth-flowing stream of activities.
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FLEXIBLE PRODUCTION SYSTEM
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AUTOMATION OF THE MANUFACTURING
PROCESSAutomation
- is at the heart of lean manufacturing philosophy
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THE AUTOMATION CONTINUUM
Traditional Manufacturing- an environment which consists of a range of different types of machine, each controlled by a single operator
Islands of Technology- describes an environment in which modern automation exists in the form of islands that stand alone within the traditional
setting- the islands employ computer numerical controlled (CNC) machines that can perform multiple operations with
little human involvementComputer-Integrated Manufacturing (CIM)
- is a completely automated environment with the objective of eliminating non-value-added activities.
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VAR IOU S TECHNO LO GIES EM PLO YED IN C IM
Automated Storage and Retrieval Systems (AS/RS)- are computer-controlled conveyor systems
that carry raw materials from stores to the shop floor and finished products to the warehouse
ROBOTICS- manufacturing robots are programmed to perform
specific actions over and over with a high degree of precisions
COMPUTER-AIDED DESIGN (CAD)- used to design better products faster
COMPUTER-AIDED MANUFACTURING (CAM)- is the use of computers to assist the manufacturing
process
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VALUE STREAM MAPPING
Company’s value stream
- includes all the steps in the process that are essential to producing a product
Value Stream Map (VSM)
- used by companies pursuing lean manufacturing to graphically represent their business processes to identify aspects of it that are wasteful or should be removed
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VALUE STREAM MAPPING