Lean Production- Doc

Added on - 19 Sep 2019

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ContentsChapter 1: Introduction...............................................................................................................................21.1 Aim....................................................................................................................................................41.2 Objectives..........................................................................................................................................41.3 Research Questions...........................................................................................................................4Chapter 2: Literature Review.......................................................................................................................62.1 Introduction.......................................................................................................................................62.2 History of lean manufacturing...........................................................................................................72.3 Review of the concept of the lean production system....................................................................112.4 The models and techniques of lean in the automotive industry......................................................152.5 Process of lean production..............................................................................................................212.6 The pros and cons of lean production system.................................................................................24Chapter 3: Research methodology............................................................................................................283.1 Type of research..............................................................................................................................283.2 Data collection.................................................................................................................................303.3 Source of data collection.................................................................................................................313.4 Data Analysis...................................................................................................................................333.5 Supervision......................................................................................................................................343.6 Support used...................................................................................................................................35Chapter 4: Analysis of data........................................................................................................................36
Chapter 1: IntroductionThe ‘Lean Production’ is a practice to reduce the inventory of the shop floor in a manufacturingfirm (Shah, 2003). The origins of this concept lie in the history of the Japanese who carry outthe manufacturing activities on the policy of tight material control, and thus they aim to achievesuch a production which is "stockless." This means that they aim to reduce the inventories to theminimum possible level and mainly to the "zero" level. It is also known `as seven zeros. It aimsto zero down the defects, setup time, breakdowns, handling, lead time and surging (Melton,2005). Thus, the companies that target lean production strive to achieve a zero inventory, andthey do this by production what is required and when it is required. With this, the storage costsget eliminated along with the possibility of the capital being tied up in the inventory.The approach of the lean manufacturing is used so that the non-value added activities could betransformed into the value added activities. The technology that is used in the leanmanufacturing has its own impetus, and it focuses on the entire operation. There are allemployees who are involved with the methods of lean manufacturing, and this concept has thedirect influence on the attitudes of the people that are a part of the company. The businessenvironment of the companies is very competitive these days, and the companies try very hard tosurvive in that competition. They have to remain competitive in the environment no matter what.In this process, if the companies get an opportunity to cut their cost, then it is very beneficial forthem. With the lean manufacturing methods and technology, the businesses get the goldenopportunity to downsize their costs, the lead time of the customers and cycle time too. there aremany companies in the country UK that are already using the lean technology , but still, thereare some areas that are yet to be permeated by the companies (Detty, 2000). Though the
technology is very useful, but still there are some challenges that are faced by the companies likethe lack of scale, the amount of investment made in the technology and infrastructure etc. tosafeguard the interests of all the people and companies in the economy, the government of UKmust maintain the standards of quality and they must help the companies in implementing thetechniques in the systems of the company.The projects related to lean management are launched in the companies with great enthusiasm.The process starts with the appointments of the project leader and then he helps the company indeveloping a vision for the future to all the team members. The team has to develop the aimsregarding how they have to make their company a lean factory. The source for these technologiesis no single; there are many techniques for this. For example, this concept has roots from thedays of Taylor and Henry ford. The techniques of lean manufacturing were then improved by thecar manufacturers of Japan. The Japanese developed the systems of Kanban material handling,and then the same concept was reintroduced in the western world with different terms like theToyota production system, the Just –in-Time concept and the Kanban manufacturing.There are many scientists and researchers who have worked on this topic previously likeDeming, Taylor, Skinner, etc. and hence the principles of the lean production are new, and theycan trace back to the work of these people (Pavnaskar, 2003). The models and the application ofthe lean production are understood from this literature which the previous researchers havegiven. But, the concept became popular when the study on the Japanese auto industry as carriedout. It became clear after that, and then it got extended to the entire spectrum of activities in thebusiness and to companies, particularly the automobile industry and the electronic companies.Though there have been some voices that discontent the lean production because they doubt the