Lean manufacturing implementationI am sure many of you already have some idea about lean. But the problem comes in lean manufacturing implementation. Most of the people understand the truth in the harsh way in this stage. Lean manufacturing do not have single solution for all the industries, and every occasion. Failing to understand this will be a fetal mistake in the process of implementation. Before even thinking about implementing, there are many fundamentals anybody has to understand. Lean manufacturing based on the lean thinking. This is the thinking I am describing on other pages of my site. Without understanding these concepts, I am sure your attempt will be a failure. To be a successful lean manufacturer, you must have a clear idea about why you are doing this? Many people start implementing lean tools and techniques even without understanding why they are used. This is no more than a waste of time and money. Do not fall into this trap. Do not try to have a lean manufacturing system because this is a buzz word. First analyze your requirements. Then understand how you can solve the problems. You will find lean manufacturing has the answer for your problems. Then start becoming a lean thinker. Understand the concepts, which lean manufacturing works on. Then start teaching others in your organization the importance of lean manufacturing in becoming a more productive workplace. When you do your groundwork, you can build the lean empire on it, without major difficulties. It is very difficult to say where you must start implementing lean manufacturing techniques. Some say it should be with a simple technique like 5S. Some say starting point should be re arranging workflow in to workcells. For me the starting point must be able convince people in the organization about the oncoming results. With a good punch in the start, the process of becoming lean will be easy. This is very important because lean manufacturing involve in many rapid changes. People are less resistant to the change when they see the results. Even though it is OK to start by implementing a part of the process, you will never be able to experience the full potential of lean manufacturing if you do not do it fully. In other words, you can not be 50% lean. Either 100% or 0%. Lean manufacturing implementation process must be well planned, step by step process. Importantly it should have contingency plans. Everything will not go as you intend or planned. It is also very important to remember that there is no one way to achieve success in lean manufacturing. Lean manufacturing techniques and tools must be used to overcome your problems. But you must always stick to the lean manufacturing concepts and principles. This is why many lean manufacturers say “lean thinking is universal not the processes at Toyota”. |
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