Are 10 products and hour equal to 120 per 12 hours in lean manufacturing context?
Lean manufacturing is a pull system. This is based on the requirement created by the customer internal or external. Based on this demand and the TAKT time, factory will be synchronized to achieve a target. If it is set to 10 pieces an hour we will have to produce 10 per hour to ensure the smooth flow of manufacturing process. 8 products or parts in the first hour will create an unmet requirement for two pieces in the manufacturing process for that hour. This will make a shortage of two pieces to the factory output for that particular hour.
One important concept in manufacturing is that time lost in production can never be re gained. That is if you loose an hour in manufacturing process for some reason, actually you will not be able to get that lost one hour again. Instead you will pump additional resources to the manufacturing facility and then balance the manufacturing rates to the intended levels.
This shows us an important fact about lean manufacturing. Lean manufacturing is based on continuous flow of value. If this is interrupted there will be a waste in some form in the manufacturing process. Monitoring the manufacturing facilities in frequent intervals will show us problems in the manufacturing facilities as bottlenecks or as delays. So it is better to achieve the production requirements, but we will have to stick to the time requirements and the rhythm of manufacturing.










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