Manufacturing & Lean Manufacturing


Definitions

Manufacturing

Refer Wikipedia Link for more  

http://en.wikipedia.org/wiki/Manufacturing

Manufacturing is the use of machines, tools and labor to make things for use or sale. The term may refer to a range of human activity, from handicraft to high tech, but is most commonly applied to industrial production, in which raw materials are transformed into finished goods on a large scale. Such finished goods may be used for manufacturing other, more complex products, such as household appliances or automobiles, or sold to wholesalers, who in turn sell them to retailers, who then sell them to end users - the "consumers".

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Lean Manufacturing

Refer Wikipedia Link for more

http://en.wikipedia.org/wiki/Lean_manufacturing

Lean manufacturing or lean production, which is often known simply as "Lean", is a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination. Working from the perspective of the customer who consumes a product or service, "value" is defined as any action or process that a customer would be willing to pay for. Basically, lean is centered around creating more value with less work. Lean manufacturing is a generic process management philosophy derived mostly from the Toyota Production System (TPS) (hence the term Toyotism is also prevalent) and identified as "Lean" only in the 1990s. It is renowned for its focus on reduction of the original Toyota seven wastes in order to improve overall customer value, but there are varying perspectives on how this is best achieved. The steady growth of Toyota, from a small company to the world's largest automaker, has focused attention on how it has achieved this.

Manufacturing vs Lean Manufacturing

 


Manufacturing

Lean Manufacturing
 
 
 1
Large lots are efficient (more is better)   
 
Ideal lot size is one piece (less the better)
 
 
 2
Faster production is more efficient
 
Balanced production is more efficient. (Faster than the necessary is waste)
 
 
 3
Scheduling & queues are necessary trade-offs to maximize m/c & manpower utilization
 
Trade-offs are bad.  Trading one for another prevents the only correct approach  elimination of the problem
 
 
 4
Production planning by push system
 
P.P.C. by “KANBAN” pull system
 
 
 5
Inventory provides safety

Safety stock is waste
 
 
 6
Inventory smooths production
 
Inventory is the root of all evils
 
 
 7
Management priorities
  • Self
  • Shareholders
  • Employees
  • Society / Customers
 
Management priorities
  • Society / Customers
  • Employees
  • Shareholders
  • Self
 
 
 
 
 
 
 
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