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14 Lean Essay

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Lean Synchronization

Week 10

Operations Management

1

In this lecture
 What is lean synchronization?
 The lean philosophy of operations
 Identifying waste in the operations system
 How does lean synchronization eliminate waste?

Week 10

Operations Management

2

Lean operations
Aims at elimination of all waste in order to develop an operation that is faster, more dependable, produces higher quality products and services and, above all, operates at low cost

Synonyms
Continuous flow manufacture
High value-added manufacture
Stockless production
Low-inventory production
Fast-throughput manufacturing
Lean manufacturing
Toyota production system
Short-cycle time manufacturing.
Week 10

Operations Management

3

Lean operations (Continued)
JIT material flow
Traditional approach

Stage A

Buffer
inventory

Stage B

Buffer
inventory

Stage C

JIT approach – lean approach
Orders

Orders
Stage B

Stage A
Deliveries

Week 10

Stage C
Deliveries

Operations Management

4

Lean operations (Continued)
Lean
approach

Traditional
approach

Focus on producing
only when needed

Focus on highcapacity utilization

Fewer stoppages

More stoppages
because of
problems

Lower-capacity
utilization, but

More production
at each stage

High inventory
means less chance
of problems being
exposed and solved
Extra production
goes into inventory
because of continuing
stoppages at earlier
stages

Week 10

Operations Management

Low inventory so
problems are
exposed and
solved
No surplus
production goes
into inventory

5

Inventories of materials, Information or customers
have similar characteristics
Of material
(queue of material)

Inventory
Of information
(queue of information)

Of customers
(queue of people)

Cost

Ties up working capital

Space
Quality

Needs storage space
Needs memory capacity
Defects hidden, possible Defects hidden, possible
damage
data corruption

Need waiting area
Gives negative perception

Decoupling

Makes stages
independent

Makes stages independent

Promotes job
specialization/
fragmentation

Utilization

Stages kept busy by
work-in-progress

Stages kept busy by...

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