CW3 Lean Manufacturing & Services Assignment Sample
Process of redesigning the company
Lean manufacturing is a process that minimizes the productivity of an organization and correspondingly minimizes the waste within manufacturing systems. The lean manufacturing process consists of several key principles such as flow, perfection, value, pull, and value stream. As one of the senior managers, it is observed the production planning and manufacturing process of company x in Charlotte. The lean methodology provides an overall concept of required changes in the process based on different individual stages as mentioned below. The mentioned different stages of lean methodology are standardization, implementation changes, control, and evaluation or diagnosis (Lai et al. 2019). According to the particular case study of company x Charlotte, the organization manufactures bicycles and has three suppliers of various machine components such as metal and plastic. The noted three suppliers are Shanghai, China, Detroit MI, and Juarez, Mexico. The lean manufacturing methods and services project describes the required factors, several applications of lean models, different techniques, and lean concepts to improve the operation and supply chain management factors of the organization.
Figure 1: Assemble plant layout
(Source: Self-created in draw.io)
The above figure shows the layout of assembly plant of the bicycle manufacturing organization. This layout is effective for reducing the wastes. With the help of lean concept the layout of assembly line has been done. Though this effective layout, the company will be benefitted.
Critical factors that influence the redesigning process
The critical factors that influence the redesigning process of a particular organization are based on the different factors such as the use or application of lean tools and methods, preparing a proper plan and following it, commitment to the lean program, allocating resources, and sharing the gains. The redesigning process also includes the essential key elements to improve the operation and supply chain management of the bicycle manufacturing organization. The noted different key elements are planning material flow and the processes, and determining and implementing several operational and quality assurance standards (Mardiana et al. 2020). The planning of the processes and material flow need to focus on the flexibility of the ideal setup, maintenance of the station, waste removal procedures of the plant, the record of arriving materials at the platform, and the daily workload of the plant. The critical factors to influence the redesigning process of a particular industry explains the required actions and decision-making aspects to increase productivity and decrease the waste of the company X, Charlotte.
Figure 2: Critical factors for redesigning
(Source: Self-created in MS-word)
Analysis of the implementation of lean tools and techniques
The analysis of the implementation of lean tools and techniques section briefly describes the various approaches and aspects based on the implementation and applications of different lean tools. The different lean tools provide an approach to reducing waste in the manufacturing process and required improvement to control the quality of the components or products. Different examples of lean tools are the five whys, Andon, Gemba, PDCA problem-solving cycle, and Jidoka. The implementation analysis of different lean tools and procedures needs to follow several steps of lean manufacturing and services. The mentioned different steps of the lean manufacturing process are reaching out to suppliers, eliminating waste, extending employee autonomy, soliciting customer feedback, shortening production cycles, and reducing unnecessary inventory (Abu et al. 2019). The implementation analysis of the mentioned various lean tools also ensures the quality testing of all products or bicycles of the particular company x, Charlotte. Implementation of different lean tools and procedures indicates the transformational process and required approaches and decision-making aspects to improve the process and develop the infrastructure of the company x.
The lean implementation tools and techniques also consider the different stages and procedures to improve the various operational functions of the company x, Charlotte. The previously noted different stages are a long-term improvement, determining value and waste of the organization, and gradually implementing the lean manufacturing techniques (Ciliberto et al. 2021). Kaizen is one of the most effective lean techniques in terms of developing the structure of the manufacturing process of company x. The mentioned lean manufacturing processes and different lean tools provide a systematic way of improving productivity, reducing waste, and creating flow in the production procedure. The noted Andon process represents the methodology based on the quicker alert of the different operators with respect to the problem present on the line. The immediate actions or alert feature of the Andon process indicates the actual problem to assist the assembly line of the organization x over other lean tools and techniques.
Critical analysis of the implementation challenges
The critical analysis of the implementation challenges section describes the different aspects, advantages, and disadvantages of the approaches. The critical analysis section includes the different challenges of implementation as insufficient management time in terms of supporting lean techniques and tools. The noted different fields of difficulty in the implementation procedure are determining the potential benefits of the several lean techniques and tools, insufficient skills of implementation, and recognizing the behavior of the workers (Yadav et al. 2020). To implement different lean procedures and tools the organization x needs to focus on the lack of standardization, several strategies for measuring poor performance, constructible designs, and incomplete designs. To improve productivity and decrease the waste of company x, Charlotte the particular organization needs to focus on removing unnecessary tasks and implementing the described different lean techniques and tools.
Reference List
Abu, F., Gholami, H., Saman, M.Z.M., Zakuan, N. and Streimikiene, D., 2019. The implementation of lean manufacturing in the furniture industry: A review and analysis on the motives, barriers, challenges, and the applications. Journal of Cleaner Production, 234, pp.660-680.
Ciliberto, C., Szopik‐Depczyńska, K., Tarczyńska‐Łuniewska, M., Ruggieri, A. and Ioppolo, G., 2021. Enabling the Circular Economy transition: A sustainable lean manufacturing recipe for Industry 4.0. Business Strategy and the Environment, 30(7), pp.3255-3272.
Jimenez, G., Santos, G., Sá, J.C., Ricardo, S., Pulido, J., Pizarro, A. and Hernández, H., 2019. Improvement of productivity and quality in the value chain through lean manufacturing–a case study. Procedia manufacturing, 41, pp.882-889.
Lai, N.Y.G., Wong, K.H., Halim, D., Lu, J. and Kang, H.S., 2019, March. Industry 4.0 enhanced lean manufacturing. In 2019 8th international conference on Industrial technology and management (ICITM) (pp. 206-211). IEEE.
Mardiana, D.P. and Alfarisi, S., 2020. Supporting Factors to Improve the Lack during Lean Manufacturing Implementation. In Journal of Physics: Conference Series (Vol. 1430, No. 1, p. 012043). IOP Publishing.
Möldner, A.K., Garza-Reyes, J.A. and Kumar, V., 2020. Exploring lean manufacturing practices’ influence on process innovation performance. Journal of Business Research, 106, pp.233-249.
Yadav, G., Luthra, S., Huisingh, D., Mangla, S.K., Narkhede, B.E. and Liu, Y., 2020. Development of a lean manufacturing framework to enhance its adoption within manufacturing companies in developing economies. Journal of Cleaner Production, 245, p.118726.
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