26-09-2016, 12:15 PM
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Abstract - Lean manufacturing is now one of the most powerful manufacturing systems in the world. Numerous plants around the world have attempted to implement or adopt it to enhance their efficiency. The purpose of this study is to investigate the approach of adopting lean, the tools and techniques implemented, the changes in the organizations, the problems encountered as well as the lessons learnt.
1. Lean
“A systematic approach to identifying and eliminating waste (non-value added activities) through continuous improvement (Kaizen) by lowering the product at the pull of the customer in pursuit of perfection.”
2. History
2.1 Lean was born in the U.S.A
• Ford production system established(1913)
2.2 Lean was first practiced in Japan
• Toyota Production System(TPS, revealed in 1917)
2.3 Globalization of lean
• Manufacturing
• Education
• Banking / Finance
• Retail
3. Ways to implement Lean
3.1 Prepare and motivate people
• Workers should be trained, recruited & trained with appropriate skills.
• Create common understanding of need to change to lean.
3.2 Employee involvement
• Push decision making and system development down to the “lowest levels”.
• Improve morale & empower people.
3.3 Share information and manage expectations
3.4 Identify and empower the best operations managers
• Remove roadblocks (i.e. people, layout & systems).
• Make it directive but empowering.
3.5 Inventive Atmosphere
• Tolerating mistakes, patience, etc.
• Encourage employees to take risks.
3.6 Installing "enlightened" and realistic performance measures, evaluation and reward systems