Question

discuss an organization in which has implemented lean in their operations. Describe in detail how this organization has implemented lean strategy to facilitate production aggregate planning and effective management of customer sales. **please answer thoroughly for a thumbs up. thanks

Answer 1

Lean manufacturing is a method used primarily by manufacturing companies. The fundamental objective behind lean manufacturing method is to develop and integrate methods and initiatives which will reduce waste from the manufacturing process of the company. One of the most famous company which has integrated Lean manufacturing in it business is Toyota Motor Corp.

Toyota Motor Corp. has developed the philosophy of Lean Manufacturing from its fundamental philosophy of Toyota Production System (TPS). Lean manufacturing has been derived from the fundamentals of TPS.

Some of the ways in which Lean Manufacturing facilitates the aggregate production and manufacturing process in Toyota are as follows:

• The production in the company is done following the philosophy of Just in Time manufacturing. Under this philosophy, the production process starts only when the customer has finalized the order. Raw material, proportionate to the order is procured. This helps in minimizing waste as well as saving the machinery from any kind of over-burden.
• The company has also integrated Jidoka in its business operations. Jidoka is automation of mechanistic jobs. The mechanistic, routine, non-critical jobs are automated so as to maintain a degree of standardization and to reduce deviations and process waste
• The executives do Gemba on a regular basis. Gemba basically means going to the source and exploring the root cause and factors, impacting the process under consideration and then take a strategic decision. This helps the company to take accurate decisions and maintain the overall quality and productivity of the company
• There are 7 types of waste which Toyota aims at minimizing, in its production process are:
  • Transporting
  • Unnecessary inventory
  • Overproduction
  • Inappropriate Processing
  • Waiting
  • Defects
  • Unwanted mobility and movement
• Toyota optimizes its every process in the manufacturing system to make it work at its fullest potential. This helps in maintaining accuracy in operations and adhering to Lean principles of reducing waste