lean & agile manufacturing

8/22/2019 Lean & Agile Manufacturing

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Lean & Agile Manufacturing

Lean Manufacturing:

Its an integrated business approach to eliminate non- value

added activities from the customer delivery cycle in operation.

This approach enables companies to respond quickly to changes

in customer demands. It is not restricted to shop floor only. Its a production strategy that aims at high levels of production

using less efforts, less time, & less materials.

Its a way of thinking, an attitude

.

The technique of lean manufacturing can be applied to every

situation in a company by finding out what the customer wants,

eliminating waste from processes & making flow continuously

according to customer pull.

Idea is to create a culture in which people at various levels of an

organization are continuously improving their productivity in

everyway. (516 MT / Kackar)


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Four Pillars of lean manufacturing

i) JIT, ii) Kaizen, iii) Cellular Technology, iv) Supply chain integration

LeanManufactur-

-ing

JITKaizen

CellularTechnology

SupplyChainIntegration

(516 MT / Kackar)


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Special features of Lean manufacturing:

Lean manufacturing produces goods with few people, littleinventory, & little wastes.

Lean ensures that each production stage processes exactly

what, how much & exactly when next stage wants it . Lean allows large variety in products without the kind of

change over costs that customised mass productioninvolves.

Lean embraces every facet of the organization sourcing,manufacturing marketing, accounting & strategic planning.

(517 MT / Kackar)


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Advantages & Limitations of Lean Manufacturing Process

Low inventory levels due to use of JIT

Simple & multitask machinery which aids variety products manufacturing.

More value to the customer.

Reduction in manufacturing lead time.

Integrates people & techniques to improve the workplace & strengthenscompanys competitive position.

Traditional vs Lean Manufacturing

JIT ( Customized)Short

Small

Pull

100% at sourceCellular type

High

High

High

Make to stockLong

Large

Push

SamplingActivity based

Low

Low

Low

1 Production2 Mfg. lead time

3 Both quantity

4 Scheduling

5 Inspection6 Layout

7 Inventory twins

8 Flexibility

9 People empowerment

LeanTraditionalSr. No.

(5

18MT/Kack

ar)


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Agile Manufacturing The word Agile manufacturing is coined to indicate the use of principles

of lean production on a broader scale. The principle underlying agile manufacturing is ensuring agility (ability tomove quickly & easily) & hence flexibility in the manufacturingorganization so that it can quickly respond to changes in the productdemand & customer needs.

This is to achieve through people, equipment, computer hardware &software & sophisticated communication systems. It integrates key functions & disciplines involved in

creating, designing, making, selling, servicing the product.. It encompasses critical operations like

technology, product & process engineering, administration &marketing /sales/services within the organizationas also vendor, suppliers, community & government.

Thus agile manufacturing is the science of business system that integratesmanagement, technology, & workforce making the system flexible enoughfor manufacturing to switch over from one product (existing) to anotherproduct (desired to be produced) in cost effective manner within theframework of the system.

Agile mfg. encompasses entire business process, i.e. planning, finance, &process design , tooling, layout, materials & inventory, cost specification,

pricing, marketing, sales & services (519 MT / Kackar)


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Agile Manufacturing contd

Made to orderCustomized Products

Orders /Quotes

Product Specifications

Sales & service options

Agile

manufacturing

Marketing

& sales

Customers Community

ManagementTechnology

Product Process

Engineering

Product

Configuration

System

Configutation

519 MT / Kackar


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Lean versus AgileAt first glance , agile manufacturing might seem to be another

way to describe lean productionThere are similarities & also differences.The major difference is that agile manufacturing takes anenterprise view, where as lean production is typically concerned

with the production floor.Lean production is regarded by some as an enhancement ofmass production methods. Agility implies breaking from massproduction mold so that a wider variety of custom products can

be made.It is viewed that subtle differences between lean production &agile manufacturing is not that important.

What really counts that both are based on similar concepts

Further both are viewed as a milestone on a path to develop newproduction theories.

(PPC 53 Sipper& Bulfin / Kackar)

lean & agile manufacturing

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