(Submit Articles) It is proven that Lean is highly successful in high volume, low variety production. Many organizations having complex manufacturing systems with mixed production line (batch production and one piece flow coexist) face excessive competition in terms of pricing and quality in their respective market segments.

Demand variability, excessive product changeovers, low volumes create the need for application of ALL the lean manufacturing tools and thereby lay the foundation for competitiveness.

At the back end, Lean Manufacturing pillars such as Total Flow Management (TFM), Total Productive Maintenance (TPM), Total Quality Management (TQM) and Total Service Management are must.

Inventory Management by application of Heijunka (load levelling) at the pace maker ensures over stocking and no stock situation are minimized or even eliminated.

Standard Work In Progress (SWIP) points are created for balancing and synchronizing the cycle times of the processes.

The entire value chain works on pull manufacturing, which is triggered through Kanban (signal) based on consumption, either by the internal or external consumer.

The processes work on demand rate (TAKT time) ensuring customer satisfaction of the highest level.

TPM is must to ensure the machines work on highest levels of OEE and support the required production rate as per TAKT time.


Author: - Jekin Thaker

Jekin Thaker, Final Year student of MTM at CEPT along with her guide: Nilesh Arora, Director, Add Value Consulting Inc. (AVCI), the leading global leanmanufacturing training & consulting firm assisting organizations transform in Totality by online lean training, workshops, counselling.

For more information please visit www.avci-lean.com, www.leanmanufacturingtraining.in, www.addvalueengg.com

Visit the Author's website: http://www.leanmanufacturingtraining.in/