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Lean Manufacturing
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[W]hile the implementation of Lean Manufacturing is not a costly journey in terms of money, it does require a long-term commitment in terms of time and effort. Once you start the Lean journey in your organization, it will be 12-18 months or more before you complete the transformation. Even then you are not done, because part of Lean is to continuously improve your processes for the total life cycle of the product.
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Lean Manufacturing is a philosophy that uses manufacturing performance as a competitive weapon. Lean Manufacturing is a systematic approach to identifying and eliminating waste in all phases of the manufacturing enterprise. Companies that successfully eliminate waste experience:
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According to a recent survey of over 1,500 pharmaceutical manufacturers, Lean Manufacturing hasn’t had the same high success rate in the pharmaceutical industry as it has in the automotive and high-tech industries. The survey was conducted by Invistics, a developer of manufacturing performance optimization solutions for complex, asset-intensive industries.
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The Toyota Production System (TPS), where Lean Manufacturing got its start, is prominently featured on the Panta Rei blog. There are regular posts about TPS as well as kaizen--the Japanese term meaning continuous improvement that has become synonymous with Lean Manufacturing and the TPS. This blog seems geared towards larger companies but there is plenty of great content here for everyone.
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Lean Manufacturing and Cellular Manufacturing improve material handling, inventory, quality, scheduling, personnel and customer satisfaction. For examples and hard numbers on these improvements see Benefits. The payoff to shareholders is significant and documented. A history of these developments is at "A Brief History of (Just In) Time."
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Most experts now agree... that Lean Manufacturing is not just a toolset. Rather it is a holistic, comprehensive, enterprise-wide program designed to be integrated into the organization's core strategy. In addition, experts in this field believe that philosophy-based Lean Manufacturing strategy is the most effective way to launch and sustain lean activities. The so called "Toyota Way," popularized by Dr. Jeffrey Liker's book of the same name, emphasizes the creation of the right kind of environment in which to grow and support Lean Thinking.
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