10.2 Lean Production
Essential idea:
Lean production aims to eliminate waste and maximize the value of a product based on the perspective of the consumer.
Nature and Aims of Design
Nature of Design
Lean production considers product and process design as an ongoing activity and not a one-off task, and should be viewed as a long-term strategy. (3.5)
Aims
Aim 9: The role of the workforce in lean production is paramount, relying on their wisdom and experience to improve the process, reducing waste, cost and production time. Recognizing this results in motivated workforces whose interests are in the success of the product.
Guidance
As DP Design Technology student you should:
Characteristics of lean production include JIT supplies; highly trained multi-skilled workforce; quality control and continuous improvement; zero defects, zero inventory
Principles of lean production include: eliminating waste; minimizing inventory; maximizing flow; pulling production from customer demand; meeting customer requirements; doing it right first time; empowering workers; designing for rapid changeover; partnering with suppliers; creating a culture of continuous improvement (kaizen)
The role of the workforce includes training, devolution in power relating to process improvement and kaizen
Consider the contribution of value stream mapping and workflow analysis to the design of an effective lean production method
Advantages and disadvantages of lean production
Concepts and Principles
Lean Production
Lean production aims to eliminate waste and maximize the value of a product based on the perspective of the consumer.
This factory tour of Fast Cap showcases many of the principles of lean production.
View Factory Tour 2.0 here and see how continuous improvement is an essential part of the company's culture.
Advantages of Lean Production
Increased productivity because of focus on continuous improvement and waste reduction
Increased quality of product because of focus on improvement and reduction of defects
Cost reduction because manufacturer is able to pass on cost savings to the customer
Increased profits through cost reduction and increased customer satisfaction
Improved working conditions for employees
Competitive advantage because of focus on cost reduction and productivity
Reduced environmental impact due to reduction of waste of materials and resources
Disadvantages of Lean Production
High capital costs due to the need to invest in JIT systems and IT systems.
Difficult to introduce to existing workforce as some workers and managers may resist the change in manufacturing approach (change can be scary!)
Dependent on a highly integrated system. If there is a breakdown in communication, deliveries, or production, the whole manufacturing system can come to a halt.
No inventory can make it difficult to respond to sudden increases in demand or create a buffer in case of a production slowdown.
Characteristics of Lean Production
JIT supplies/system:
The correct amount of material and parts delivered at the right time to eliminate inventory
Highly trained, multi-skilled workforce:
Using experts in production engineering and to ensure no time and materials are wasted
Zero inventory:
Manufactured products are shipped immediately, avoiding the need for managing inventory.
Zero defects:
Avoid defects by ensuring no that substandard materials and production practices are used.
Quality control and continuous improvement:
An active approach to improvement; Quality control and checks happen at all stages of the production
Principles of Lean Production
Minimizing inventory to reduce inventory management costs
Elimination of waste: Wasted time, wasted material, reduction of errors and defects, etc.
Designing for rapid production changeover to allow for efficient retooling and changes in production goals
Pulling production from customer demand: a JIT system is used to drive production rather than a JIC system
Partnering with suppliers in order to operate a successful and efficient JIT system
Doing it right the first time emphasizes quality and reduces waste
Maximizing production flow in order to take advantage of economies of scale
Empowering workers as they are the most valuable resource in the company
Focus on Kaizen – A philosophy of continuous improvement by all involved (managers, designers, workers, etc.)
Meeting customer requirements and taking seriously every single customer complaint and opinion of the product or service; the flexibility of the lean production system determines the degree to which a company can meet each individual customer’s needs.
Value Stream Mapping and Work Flow Analysis
Both Workflow analysis and Value Stream Mapping are essential tools for lean production processes and work in tandem with each other.
Value stream mapping is concerned with the big picture of the production process. The goal is to identify areas for improvement and to optimize the overall process. Value stream mapping is a lean production management tool used to analyse current and future processes for the production of a product through to delivery to the consumer.
Workflow analysis is concerned with the details of the production line. It considers the sequence, tools and even worker movement to ensure the highest possible efficiency in the system.
Product Family
A product family is a group of products that have common components or elements.
By creating a family of products that share common components manufacturers can create a competitive advantage. Products in a product family share common parts, manufacturing processes and architecture. This has several advantages for manufacturers:
Reduced manufacturing costs because products use similar parts, techniques, suppliers
reduced R&D costs as changes are typically incremental and made to the architecture of the design; There is no need to design a new product from the ground up.
Attract a range of customers as each product in a product family can be targeted to the slightly different needs
Easily adapt to market demand
Waste is reduced as waste from one product can be used to manufacture parts for another
The Apple 5SE is an example of market pull whereby market demand for a cheaper phone with updated technical abilities was successfully introduced.
Source: Engaget
Resources
Article: Apple and Product Family Engineering:
Investopedia entry on Product Families and marketing
Fitbit is a good example of a product family that share similar or the same technologies while also differentiating to meet different users needs. The firmware (a type of software) running on Alta, Charge, Charge 2, and Charge 3 is more or less the same. The overall architecture of heart rate sensors, screens, wrist bands and clasps of the models is more or less the same, allowing the company to utilize similar manufacturing techniques. The differences between different models (waterproofness, wireless payment, heart rate tracking, linking with smartphone, etc.) allow users to choose a device that meets their needs. Each person in a family for example, from children to active adults, could find a model that meets their needs.
Fitbit's website offers a sophisticated tool to help customers learn about and choose the fitness tracker that best matches their needs.
A review by TechRadar of the various Fitbit models includes a guide to helping consumers choose
Common dimensions allow for the product to be customized for different user needs
A common form and mechanism that is differentiated by aesthetics, color, and texture (strap)
Lead Time
Lead time refers to the time between the customer placing an order and the the item being delivered to the customer. Depending on the type of product lead time can be measured in days or weeks.
Kaizen
Kaizen is a philosophy of continual improvement. It has played a significant role in the success of many Japanese companies, most notably Toyota.
Central to the success of Lean Production is the emphasis on the workforce as the most valuable component of the manufacturing system. This is founded in the belief that no system is perfect, and thus the users of a system (the workers) are best situated to suggest improvements.
Training a highly skilled workforce develops an intimate understanding of the production process and empowers workers to identify areas for improvement. Because such an approach depends on empowering each employee, across all levels of the company, such systems are typically more horizontal rather than hierarchical in nature. This characteristic of lean production systems can make it difficult to introduce to existing non-lean production systems.
In this video of a Toyota manufacturing plant, notice:
how the workers are involved in making decisions to improve the production process
how principles of lean production are implemented
The 5 S's
The 5 S’s are developed from Six Sigma methods and are a method for organizing the workspace with the goal improving the efficiency of production
Sort: Keep only the necessary items in the workplace.
reduce time looking for items
reduce distractions,
increase safety
simplify inspection
Set in order: Organize the workplace or workstation to optimize and streamline efficiency
increase efficiency of workflow; completed items are removed as soon as possible
Fixed and labelled locations for tools and materials
Shine: Keep the workplace clean and organize in order to eliminate waste and maintain efficiency
keeping workspace clear, clean, and organized to improve safety and eliminate waste or spoilage
Standardize: Set standards for a consistently organized workspace
ensure workers know their responsibilities
Sustain: Maintain and review standards
perform regular audits and provide time for review and improvement
7 Wastes in Lean Manufacturing
The 7 (sometimes 8) wastes in lean manufacturing identify the areas where waste can happen and negatively affect a lean production system. These areas also present opportunities to improve the manufacturing system.
In the examples above, many of the improvements are based on identifying and responding one or some of these types of waste.
