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Viewing 16 posts - 1 through 16 (of 16 total)
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  • #28989

    Fahim
    Participant

    what is lean manufacturing? and how can it be applied in a medium to large manufacturing unit.

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    #73112

    Ali Askari
    Participant

    Fahim, Either you are new to Improvement or Quality process – or looking for few quick examples, to get few quick hits at work. Each process and industry is different, one need to learn to apply the improvement technique and skills – as required. Whatever, there is no short cuts! Few tips
    1. Do some research on the topic
    2. Buy few books.
    3. Get some reading under your belt
    4. Then contact few consultant with expertise in “Lean” manufacturing.

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    #73117

    RR Kunes
    Member

    Lean manufacturing is a methodology similar to Six Sigma. The difference between Lean and Six Sigma is the tools and the aim of the methodology.
    Lean looks to improve the process flow (reduce throughput time) thereby enabling lower inventories and more flexibility.
    Six Sigma’s aim is to reduce variation in processes. It’s toolkit contains variation reduction tool along with statistical analysis tools.
    Buy a copy of “Lean Thinking” by J Womak for a good overview of lean.
     

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    #73119

    Eddie
    Participant

    Lean Mfg. – Simply means to get lean, eliminate wastes of all types.  Then make sure the waste you eliminate doesn’t reoccur

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    #73120

    James A
    Participant

    “All types of wastes” for Lean are usually identified as:
    Scrap, Over-production, Inventory, Motion (people and parts), Processing (i.e. re-work/hidden factories/uneccessary machining), Transport, Waiting.
    The parallels between Six Sigma and Lean are pretty obvious – the  hard part (as for Six Sigma) is making sure the changes stay, and the old ways do not creep back.  E.g. when ‘new’ staff appear on the line or contract personnel are brought in.
    Regards
    James

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    #73131

    Ali Askari
    Participant

    Drop me an email, I have excellent slides on Kazien, Lean and Six Sigma  and few articles on above topics.
    regards
    Ali Askari

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    #73144

    Fahim
    Participant

    thanks James, Kunes, Eddie and Ali. your replies have provided me the direction i was looking for.regardsfahim

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    #73165

    Cone
    Participant

    I disagree that the aims are different.
    Both are to make your organization more responsive. You have responsiveness issues that are because of how work is organized (Lean) and you have responsiveness issues because of mistakes bing made in the process (Six Sigma).
    I have seen what was called an excellent Lean implementation where waste was rampant because of mistakes (several of the companies cited by Womack) and I have seen what was called an excellent Six Sigma implementation where waste was rampant because of poorly defined flow.
    Lean and Six Sigma are actually two sides of the same coin and all your change agents should be versed in both – then they should avoid hanging lables on the work. It only confuses the very resources you wish to engage.

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    #73172

    O’Grady
    Participant

    Fahim,

    Nothing I’ll add conflicts with what has been said before.
    Think of Lean as a philosophy based both thinking and tools developed by a long line of people and organizations culminating with the Toyota Production System (until the next breathrough).  Think of it as an evolving philosophy, not a bag of tricks or a religion.
    Think of Six Sigma as the latest of the tools and thinking which supports the principles of Lean.  There is little or no conflict between the two and their objctives.
    Take a look at http://www.lean.org/ (Lean Enterprise Institute) where you’ll find the Lean fraternity having a parallel discussion to the one in this forum.  (If only we could find a way of getting two to do a bit more sharing.) By the way, it was founded by James Womack
    Use the Keyword search of this forum to review many of the parallel discusssions on the subjects of LEan and its relationship to Six Sigma (and even terrorism!!!)
    Hope this helps.  Have fun.

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    #73177

    Bill Williams
    Participant

    to make, lacking richness, sufficiency, or productiven, from raw materials by hand or by machinery
    Main Entry: 3leanFunction: adjectiveEtymology: Middle English lene, from Old English hl[AE]neDate: before 12th century1 a : lacking or deficient in flesh b : containing little or no fat2 : lacking richness, sufficiency, or productiveness3 : deficient in an essential or important quality or ingredient: as a of ore : containing little valuable mineral b : low in combustible component — used especially of fuel mixtures
    Main Entry: 2manufactureFunction: verbInflected Form(s): -tured; man·u·fac·tur·ing /-‘fak-ch&-ri[ng], -‘fak-shri[ng]/Date: 1683transitive senses1 : to make into a product suitable for use2 a : to make from raw materials by hand or by machinery b : to produce according to an organized plan and with division of labor3 : INVENT, FABRICATE4 : to produce as if by manufacturing : CREATE intransitive senses : to engage in manufacture- manufacturing noun
    Hope this clarifies things for you.

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    #73198

    Fahim
    Participant

    Owen, thanks for the guidance. actually i was trying to develope a layman’s definition of the subject in an effort to equip myself for the introduction of the lean to my production people. we manufacture paint, sometimes overproduce without knowing that this will not benefit the company. i was attracted to the lean with the concepts in my mind that it is some different kind of a philosophy that uses all known process improvement techniques.
    regards, fahim.

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    #73214

    fernando
    Participant

    Ali,
    I am also interested in the slides on Kazien, Lean and Six Sigma  as well as the articles on these topics. Please forward me this material to the e-mail writen bellow.
    [email protected]
    Thank you,
    Fernando

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    #73220

    Ali Askari
    Participant

    Fahim,
    Here are few useful sites on “Lean”
    http://www.lean.org/
    https://www.isixsigma.com/library/content/c020225a.asp
    https://www.isixsigma.com/me/lean_manufacturing/
    https://www.isixsigma.com/library/content/c020204a.asp
    https://www.isixsigma.com/offsite.asp
    A=Fr&Url=http://www.autofieldguide.com/articles/109907.html
    http://web.mit.edu/manuf-sys/www/amb.summary.html
    This set will make a good reading and give you few ideas, for improvement in your paint manufacture. Plus, have you considered Lean vs Six Sigam.
    Ali Askari

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    #73221

    Bobby
    Participant

    hi,
    could you also share me your slide about that topics?
     
    Thanks a million
     
    Sincerely
     

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    #73287

    Mike Carnell
    Participant

    Fahim,
    Most of this is really good advice. I am not sure if Womack still does it but he used to post the slides from his presentation on his website (lean.org) and he didn’t care if you down loaded them.
    A lot of this comes from the Toyota Production System (TPS). Womack write a lot about it as an outsider. Shingo was an insider, somewhat, and his books are worth reading. Monden was also an insider and his book is also worth reading.
    It would be a huge mistake to go into this without reading “The Goal” also.
    If you are interested in a seminar. IIR (Institute for International Research) will present a conference on “Practicalities of implementing Lean” next month in Chicago. They have a demo by Roy Piciacchia from Lockwood Greene. This is really a first rate demo and can be leased for your own use or they will do it for you (before anyone gets emotional about self promotion I have nothing to do with Lockwood Green other than I have watched the demo a couple times and it always gets good reviews). It is one of the best I have seen and it is fun.
    Good Luck.

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    #73308

    Fahim
    Participant

    Ali, could you please send me the slides etc. regards.

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