Question

Hi i have to write thesis type paper 5-6 pages for theory and best practice of lean supply chain management on following topics.

1. Lean Layout ( its theory and best practice)

1.1 Manufacturing Cells

2. Inventory and setup time reduction (Theory and best practice)

3. Small batch Scheduling( theory- what exactly it is? and best practice Dell example or may be different)

4. Continuous Improvement (theory and give brief example of best practice )

5. The Impact of Lean Supply Chain toward Sustainability

Answer 1

1. Lean Layout It is related to facility reorganization. It focuses on elimination of wastages and reducing inventory level by adoption of Just in time techniques. It can be used in offices and plants. It designs the place in such manner that reduces the need of workers and so brings down costs. In plants it focuses on realigning processes and layout of machines and labor.

E.g. U-shape layout is most popular and best in this category in manufacturing facilities. Majority of banks are using lean layout for customer convenience and employee assistance. Value-stream mapping is used for establishing lean layouts.

1.1 Manufacturing Cells: Its principles for manufacturing are

• Optimize the efforts of all involved in production, designers, engineers etc.
• Being customer focused and dropping activity / feature etc. that render no value to them.
• Automate processes to improve quality
• Speed in delivering to customer, go for JIT
• Have knowledge management systems
• Being agile
• Respect human dignity

2. Inventory and setup time reduction

Set-up time or time taken in retooling indicates lead time.

Organizations are considered highly capable if they have flexibility in it according to customer demands. They can alter products / services in line with time constraints. The company with shorter set up time has small lead time.

Single Minute Exchange of Dies, a Japanese technique can do so.

• Existing process of set-up is analyzed to know the activities that happen during setup and which take place outside set up process.
• While machine is operating all outside activities not in set up can be completed. The other activities are performed once machines are halted.

Inventory reduction:

• Companies can go for vendor alliance program for getting inventory when required and customized to their business need. This will lead to reduction in inventory investment and carrying cost.
• Bringing down the lead time among supply chain partners
• Automation in inventory management and supply chain

3. Small batch Scheduling

The fabrication of parts of finished product is produced in batches. The final product is driven by demand of customer. The manufacturing is done according to order specifications.

Small batch Scheduling eliminates wastage of resources. It leads to customization. It is used in paper mills.