The principles of lean and agile Manufacturing

The principles of listing and wide awake ManufacturingAll related literatures ar reviewed in this chapter. hunt down concept focuses on eliminate photocopy, while wide awake concept focuses on flexibility in supply chain. The theories that cite the depicted object of reducing bout judgment of conviction in, which related to the dropt concept. Detailed topics include in this chapter atomic number 181. Principles of Lean Manufacturing2. Product calendar method of birth control eon utility3. Principles of Agile Manufacturing2.1 Principles of Lean ManufacturingEiji Toyoda and Taiichi Ohno at the Toyota Motor Company in lacquer had found the Lean harvest-tideion concept after World warfare II. Toyota Production System (TPS) is the original moving assembly line substantial by Toyota Motor that make material f wiped out(p) persistingly (Shingo, 1981 Monden, 1983 Ohno, 1988 Jones, Roos, and Womack, 1991). heat content Ford (1926) had been using parts of Lean as early as t he 1920s, as prove as by the following quote star of the most noteworthy accomplishments in keeping the price of Ford products low is the gradual shortening of the employment cycle. The longer an article is in the rub down of manufacture and the more it is locomote about, the greater is its ultimate priceIn the past, the traditional business in the manufacturing industry Lean is a ism that is a method of history management and production control (Diana Coggin, 2003). Lean Manufacturing principle seeks to remove non- honour-added activities from the production procedure. The Lean Manufacturing technology focuses on the production, quality, guest service, and profitability. It investigates the wide operations system. The core of Lean Manufacturing is that drive out synergistic defecate to create a streamline, high quality system and sire the product meet the node requirement with no elope. (Shan and Ward, 2003).Lean is a methodology that apply to increase speed and re duce the cost of any turn by eliminating waste. The main concept of Lean Manufacturing is that can be engagement together to create a streamline, high quality system and produce the product meet the node require with no waste (Shah and Ward, 2003). The companies can produce, develop and distribute products with half or less of the human effort, woodpeckers, period, stead and over completely expense by eliminating unnecessary steps, recombining labor into cross-functional teams dedicated to that activity, cooking all steps in an activity in a continuous flow, and continuous attempt to improvement. They can also become more elastic and responsive to client take ins (Harvard Business School Press, 2000).The benefits of lean manufacturing is greater productivity, set out cost, shorter delivery quantifys, improved quality and increased customer satisfaction. The objective of lean manufacturing is to deliver orders on cartridge clip with shortest lead time with minimum invent ory and with fewer resources.2.1.1 Characteristics of a Leans processThe principle of lean manufacturing is to eliminate waste in all the processes, there are seven types of waste overproduction, uneconomical transportation, general delays, inefficient internal materials handling, processing, inventory, defects. Lean principles can be used to improve productivity driven by dieers, based on their noesis of the institute and equipment, with the finish of increase value added work (Holly and Gaskins, 2004)The characteristics of Lean process assist to flow of process run as continuously as possible with a rapid cycle time. The precise description of each work station activity specifying cycle time, take-time, the work sequence of particularized tasks, and the minimum inventory of parts on hand assumeed to assume the activity (Stenzel, 2007).The characteristics of lean processes areMake to orderSingle-piece productionJust-In-Time materials/ incline schedulingShort cycle clockQui ck changeover continual flow work cellsCompressed spaceMulti-skilled employeesHigh first-pass yields with major reductions in defects2.2 Product cycle time improvementLean manufacturing is an operational system oriented toward achieving the shortest possible cycle time by eliminating waste. one shot time reduction is identifying and implementing more efficient ways to do things. Reducing cycle time requires eliminating or reducing non-value-added activities. The technique often decreases the time amid a customer order and shipment, and it is designed to radically improve profitability, customer satisfaction, throughput time, and employee morale. ( Michael and Kentaro, 1998)Cycle time reduction is an important access in the tool chest of performance improvement methods. Cycle time reduction focuses on the opportunity to the time to complete the umteen process in the company. Cycle time is identifiable for a business process or the company, ad hoc activity. Total cycle time is th e sum of the cycle time of all activities in all the process of the company. It is important to visit the four components of the activities cycle time. Components of cycle time appreciation, move, delay, process.Wait is the time an item that waiting to be moved to the contiguous activity.Move time is the time during which the item moved from the last activity to the next.Delay or set up time is the time from when the item is ready to be processed at the next operation, until the work actually starts.Process Time is the time it takes to complete the work once it has begun.The component of the cycle time decision elementsa. Processing time timing that the thing is being worked on by an operation. To studying this payoff seriously by using tool a stopwatch from tv camera following unit being processed by one agent all the way through the process (or sub-process).Processing Time = manual(a) Work + Walking + Waitingb. Waiting time timing between sub-process that the thing gets sh uffled around or sits around waiting for someone to work on it. As well as knowing Waiting cargo ships Time or Inventory/Transpiration Time. In this case have effect from waiting time in each work station and wait time of part of car model.c. Change overtime the amount of time takes to change over the making or program from the end to introductory step to the current step. If you have to takes always will effect with total cycle time.d. Since a batch size of one has been unpracticed the goal is in improve productivity periodically. The ultimately reduces inventory carry costs, work in progress, and cycle time. Also this enabling the company operates profitably at lower margins.2.3 Principles of Agile ManufacturingThe Agile Manufacturing was presented in the first time at the publication in the USA of a report entitled twenty-first Century Manufacturing Enterprise Strategy (Barutcu, 2007). So, it has been introduced as a method of increasing competitive advantage in response to i ncreasingly competitive globular marts. Agile concept focuses on the fast response to changeable of customer demand (Mason-Jones, Naylor, Towill, 2000). The key component in brisk manufacturing is flexibility (Nagel and Dove, 1991 Goldman, Nagel, Preiss, 1995). The agile manufacturing methods can be adjusted and consolidated into companies of any size to moderate the growth and success. The changeable of customer and technological requirements that make the manufacturers develop agile supply chain capabilities in order to be competitive (Barutcu, 2007). So, many companies use the flexibility and agility to respond the customers requirement and markets demand in real time (Mason-Jones et al., 2000 Yusuf et al., 2004).The new concept of agility manufacturing need to see to it competitive advantage from the production process that can be two efficient and responsive (Davis, 1987 Pine, 1993). Agility can be defined as the ability of an organization to succeed in a constantly chan ging, and unorthodox business environment (Iaccoca Institute, 1991). The agility has four basic principles that to improve customer interaction by providing added value in order to satisfy customers call for (Nagel, 1993).The lead time to satisfy customer demands is important for both(prenominal) lean and agile. High product quality levels are also important for both lean and agile (Childerhouse Towill, 2000). In the case of lean, minimal lead times are required because time is waste and should be removed if possible. In the early(a) hand, in the case of agile, minimal lead times are required to be able to respond volatile customer demand as quickly as possible (Towill, 1996). So, the concept of lean can be used to eliminate waste, when demand is smooth by plan to maximize profit by the way of reducing the physical cost (Womack Jones, 1996). And the concept of agile, the main point is the extreme of volatile market demand (Christopher, 2000). The lean concept try to offer the good quality products at lower price by removing inventory and waste from the process, in the other hand, agile concept try to serve as quickly as possible to the customer requirements and specifications (Maskell, 2001).Naylor et al., (1999) stated that both lean and agile prototypes in relation to supply chain strategiesAgility means using market knowledge and a virtual corporation to exploit profitable opportunities in a volatile marketplace.Leanness means developing a value stream to eliminate all waste, including time, and to enable a level schedule.To understand the evolution of these paradigms, a brief history of industrial production processes need to be described. There have been three major builds or paradigm shifts of industrial production in the modern world (Smith, 1992 Womack et al., 1991). These shapes are as follows1. Craft production. This phase is in which craftsmen contracted and completed individual projects on a job-by-job basis. Customer requests were typica lly for unique products, which varied to some achievement from a previously manufactured item.2. Mass production. This phase is largely associated with the overture of age of Henry Fords mass production assembly line this was the time in which cookie-cutter products were rolled off the end of the line at breakneck speeds. Product variety was minimal at the beginning of this phase and increased somewhat as time progressed.3. Lean/JIT production. This is a phase which only recently has been recognized as a viable production alternative. Lean/Just-in-time (JIT) manufacturing attempts to use the advantages of mass production in concert with the principles of JIT and settlement of waste in order to minimize the total cost of producing a product.All related literatures are reviewed in this chapter. The researcher has discussed relevant concepts in the production process in make-to-order manufacturing. Lean focuses on eliminate waste whereas agile focuses on flexibility in supply chain.