Lean Manufacturing SystemWhen different elements of Lean Manufacturing correlate themselves, they form a system and are known as Lean Manufacturing systems. Also known as Manufacturing strategy, a system shows how these elements work together to reinforce the business objectives of a manufacturing process. The core of a Lean Manufacturing System The elements which form a hub of the Lean Manufacturing system are the basic elements of Lean. It is these basic elements which drive the whole process of Lean Manufacturing ahead. The most critical elements forming the central part of a Lean Manufacturing system are Cellular Layouts and Pull Scheduling which form the major part of the infrastructural requirements of a Lean Manufacturing system. Techniques like 5S, Continuous process improvement etc act as process flow enhancers which improve the flow of communication between two stages of a production process. Cellular layouts and small setups improve information and material flow across the production process. Production happens in small batches which further reduces the inventory wastes. The fact that production happens in small batches ensures that transportation costs are minimized at all times. Pull Scheduling enables smoother operations of the entire process. Smaller batches of the product which result from the Cellular Layout system of production are of better quality. Good team work amongst team members of the production cycle ensure that the setup of cellular layouts is in the best format possible. Additionally, this team-work also acts as a good feeder for implementation of Six Sigma projects. There is a classic two-way interaction between Pull Scheduling and Cellular Layouts which enhances production value and quantity. Pull Scheduling results in smaller batches of the product at enhanced quality. This also ensures that the inventory costs are reduced greatly. A closed cycle between faster setup times and improved setup skills exist this way - professionals with improved setup skills set up units in faster times which enhances the times of production of small batches. These process loops and cycles also form an integral part of what is known today as System Dynamics or Industrial Dynamics. The most complicated part of a manufacturing process is to understand the technological and the human aspect of the process flow and correlate them. The complex theoretical analysis which comes out of this adds to a lot of chaos in terms of process variability, time delay etc. Lean Manufacturing addresses quite a bit of these concerns to ensure that manufacturing processes are optimized by reducing waste and setup times. Based on the complexity of the manufacturing model, a lean manufacturing system should be evolved to ensure that all the inputs and components of the manufacturing process are considered in the process flow. A Lean Manufacturing system which encompasses all these (which in all probability, it does) can generate maximum profit for a company off its manufacturing processes. |