The lean machine
Lean manufacturing has a definite set of inputs and it is intended to give certain set of outputs. It consumes energy in various forms and requires maintenance in operation. It requires setup and time to time health checks. Objective of lean is to generate the desired output by optimizing the resources used. Sounds like a machine. In fact it is. It is a very productive machine.
Lean systems can be modeled as machines. This will give us clarity in thought process and will make it easy to understand systems. A lean system gets inputs in the form of raw materials, electricity, human resource and management. It creates the products or the services by utilizing them. The system is aligned so that it can give output of one piece using one piece of RM as the input. In other word there is no requirement to enter inputs in bulk to get the output. And this large machine is consisting of number of interdependent small machines.
The lean machine is intelligent enough to understand the variations occurring in it. And it will correct those variations by itself. If it can not do the correction by itself, it will stop and will get the third party involvement in correcting. It will not pass the defective parts forward. So this machine is fool proofed.
This machine works with simple logic. When there is a requirement it will pull the raw materials or the semi finished goods from the early process and will process them. There will be minimum amount of products inside the machine at any given time making the WIP very low.
Continuous monitoring and upgrades are required to make sure this machine works correct. Improvements and fine tuning will make the machine more and more effective. People are the gears and electronics and the computer chips of this machine. If they do not work correct, the machine will fail. So it is very important to keep people motivated. Training and educating people is also very important.
Lean machine needs energy. This needs to be provided by top management. Part of the energy is generated within the system itself with the effects of synergy. Starting the machine requires lots of energy. But once started it can run with very little of it.
Lean is an effective, efficient and very simple machine. Creating and operating this will take time and effort. But once done it will add great value to the organization.
Lean systems can be modeled as machines. This will give us clarity in thought process and will make it easy to understand systems. A lean system gets inputs in the form of raw materials, electricity, human resource and management. It creates the products or the services by utilizing them. The system is aligned so that it can give output of one piece using one piece of RM as the input. In other word there is no requirement to enter inputs in bulk to get the output. And this large machine is consisting of number of interdependent small machines.
The lean machine is intelligent enough to understand the variations occurring in it. And it will correct those variations by itself. If it can not do the correction by itself, it will stop and will get the third party involvement in correcting. It will not pass the defective parts forward. So this machine is fool proofed.
This machine works with simple logic. When there is a requirement it will pull the raw materials or the semi finished goods from the early process and will process them. There will be minimum amount of products inside the machine at any given time making the WIP very low.
Continuous monitoring and upgrades are required to make sure this machine works correct. Improvements and fine tuning will make the machine more and more effective. People are the gears and electronics and the computer chips of this machine. If they do not work correct, the machine will fail. So it is very important to keep people motivated. Training and educating people is also very important.
Lean machine needs energy. This needs to be provided by top management. Part of the energy is generated within the system itself with the effects of synergy. Starting the machine requires lots of energy. But once started it can run with very little of it.
Lean is an effective, efficient and very simple machine. Creating and operating this will take time and effort. But once done it will add great value to the organization.
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