What Is Lean Manufacturing

The Supply Chain Journal

Time, resources, man-hours, supplies, and capacity are just some of the critical areas where an approach known as lean manufacturing is vital. Managers and team members must understand manufacturing processes and how lean manufacturing can affect the final outcome.

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Going Digital for Manufacturing

DELMIA Quintiq

However if your company needs to reduce manufacturing lead times, streamline inventories, boost efficiency, make the right promises to your customers, and all of this at the same time, you need to challenge this status quo. “I do not need a Production Scheduling solution!”.

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How to Sustain a Lean Culture in Manufacturing & Supply Chain

GlobalTranz

Today I will discuss how a company can sustain a lean culture once they have implemented lean practices in order to achieve continuous improvement. Your company has started the lean journey, but how do you sustain it? Let's first talk about first setting the stage, then give you practical practices and tactics to achieve a sustainable lean culture, and then provide core key performance indicators (KPIs) to track your progress. Lean Culture by Creating "Standard Work".

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Lean Manufacturing

LeanCor

A motor manufacturer’s warehouse space and on-hand materials were growing exponentially as it received, processed, and stored material for potential future use. As a result, warehoused inventory increased from one to seven warehouses due to lack of a defined inventory and replenishment strategy. LeanCor used PFEP as the foundation of the future state parts strategy and 5S to sustain optimal inventory levels and locations.

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Lean Manufacturing: Is it Really Worth It? 16 Big Benefits Say, “Yes.”

GlobalTranz

Customer expectations of reliable quality and rapid delivery forces today’s manufacturers to either shorten cycle times or lose business. Lean systems have provided a formidable operating strategy for leaders determined to achieve and maintain optimal operational systems and customer satisfaction levels. There are multiple good models for lean manufacturing operations. Who Needs Lean Manufacturing? Holding areas are maintained for excess inventory.

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When is Inventory Too “Lean”? Finding the Right Balance

ToolsGroup

I learned about “lean manufacturing” (or simply “lean”) back in the 1990s when I met James Womack and read his book “ The Machine that Changed the World ”. Based on MIT's five-year, fourteen-country study – one of the largest and most thorough ever undertaken -- the book describes the entire managerial system of lean production. In the last twenty plus years “lean thinking” has fundamentally changed the way many companies, and sometimes whole industries, operate.

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Understanding Lean and the 8 Wastes

The Logistics of Logistics

Understanding lean and the 8 wastes is important for all operations people including logistics and supply chain folks. The concept of lean (and the 8 wastes) originated in the manufacturing sector where it was first recognized that eliminating waste in the system led to much bigger profits. Henry Ford and his team at Ford Motor Company discovered lean along with the assembly line, even though they didn’t necessarily use the term lean. Excess Inventory.

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Lean Transportation: Are you Using Lean Thinking for Transportation Management? If not, Why?

GlobalTranz

Lean is a new way of doing business. For shippers, culture and behavior have to change to apply Lean Transportation thinking. Lean thinking focuses on the elimination of all waste (where waste is defined as any non-value added process) and bringing value to the customer , beyond the customer’s expectations. The “Them (company leadership) versus Us (shop floor associates)” mentality also needs to change for Lean Transportation to " WE.

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What Is Manufacturing in the 21st Century

The Supply Chain Journal

When people think about manufacturing and the supply chain , most would never think about the global scale and the technological advances it has morphed into today. But still, with manufacturing comes waste. Defining Manufacturing in Today’s World.

5 Reasons Why You Need to Stick with Lean Manufacturing Principles

USC Consulting Group

One of the most successful and widely utilized in the manufacturing sector is just-in-time inventory. Since manufacturers kept their own supply levels low and couldn’t ramp up production due to social distancing measures, stockers could barely keep up with the pace of demand.

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Lean Manufacturing Driven by Rapid Return on eKanban Technology Investment

synchrono

Lean Manufacturing relies heavily on trusted relationships with suppliers and pre-negotiated terms of engagement. Through the use of supplier quality certifications and blanket (long-term) purchase orders, a manufacturer can accurately and effectively calculate the optimal level of inventory needed to fulfill demand requirements through the duration of replenishment lead time. Eliminating inventory waste. Pull Manufacturing with Kanban.

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9 Steps to Establish the Lean Supply Chain: A System of Interconnected & Interdependent Partners

GlobalTranz

Top management knows that lean can add value , but many still haven’t moved past the initial education stage into full-scale lean supply chain implementation. One reason may be that they haven’t made the paradigm shift as to how to implement lean. The Lean Supply Chain is a system of interconnected and interdependent partners that operate in unison to accomplish supply chain objectives. o Space—holding places for unnecessary inventory.

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Lean versus EOQ? What’s best for your organization?

Kinaxis

In no time at all we were debating between lean versus EOQ. It doesn’t matter if you’re a technician working on the shop floor or an executive in the board room, if you’re in the business of manufacturing then this is a conversation you’ve had before. EOQ attempts to optimize lot size by balancing manufacturing cost ( Fixed + variable costs) with things like inventory holding costs and capacity utilization. You’ve ‘gone lean’ but aren’t!

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Lean Warehousing

LeanCor

Lean Warehousing – From Paradox to Operational Excellence. Before we start talking about Lean Warehousing, can you tell us a little bit about LeanCor Supply Chain Group? We want to help our customers succeed in their quest for lean and operational excellence. Relative to our topic today, Lean Warehousing, is it a big part of your operations? What we know for sure is that lean warehousing, just by the nature of the term itself, can be a paradox at best.

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Lean Culture

LeanCor

Building a Lean Culture: A Food and Beverage Case Study. LeanCor has partnered with food and beverage manufacturers, distributors and resellers of an assortment of products ranging from bottled water and frozen dinners, packaged snack foods and candies, to refrigerated deli sandwiches. These are companies that embrace lean and recognize that the organization is only as good as its people. Lean Culture Current State: Customer Challenges in the Food and Beverage Industry.

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Warehouse Cost Reductions: 3 Understandings Driven By Inventory Management & Lean Principles

GlobalTranz

Today, I will now address how a focus on inventory will allow for warehouse cost reductions as well. A Focus on Inventory Control Begets Warehouse Cost Reductions. First, look at inventory as MONEY/CASH. Inventory cost is defined as the cost of holding goods in stock. If you are looking for warehouse cost reductions, chances are you are stocking too much inventory. Understand Data Integrity to Reduce Inventory Costs. Lean is a new way of doing business.

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Lean Principles and Sales & Operations Planning (S&OP)

Logility

Many companies have high hopes when they set out to establish a Lean operating environment. A growing body of knowledge and experience indicates that advanced Sales & Operations Planning (S&OP) may be the key ingredient for Lean success. Lean applied to supply chain operations is all about creating capabilities that efficiently move materials from raw through finished product, and then to the customer.

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Facilitating Lean with Synchronized Planning & Optimization

DELMIA Quintiq

Manufacturers today are being challenged to anticipate new product introductions while reducing costs and protecting profit margins. As an example, we can look at the automotive plastics manufacturer Novares. Manufacturing can play an important part in supporting these key strategies.

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Applying Lean 6 Sigma Principles to the Supply Chain

Logility

Fifteen years ago, I worked for a company that embraced Lean 6 Sigma as a core operating fundamental. Just about every member of the management team was a Lean 6 Sigma Black Belt and many had attained a level of Master Black Belt. As Director of Logistics and Planning, part of my responsibilities were to manage our relationships with outsourced manufacturing partners including quality. Today, Lean is a concept, a philosophy, a practice and a set of tools all wrapped in one.

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Leaning Towards S&OP/ IBP

Logility

Many companies have high hopes when they set out to implement a Lean improvement program. A growing body of knowledge and experience indicates that Integrated Business Planning (IBP) may be the key ingredient for lean success. Lean is all about creating a physical environment that enables material to flow efficiently from raw through finished product to the customer. The perfect enabler for Lean success is called Integrated Business Planning.

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Lean Thinking Revisited

Operations and Supply Chain Management

One landmark in the lean revolution for retailers was Walmart ’s decision in 2006 to thin out inventory by $6.5 The supply chains for consumer goods in the U.S. remain under strain months after pandemic lockdowns triggered a range of sudden and surprising shortages.

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Top 10 2020 Manufacturing Trends

IQMS

Bottom Line: 2020 manufacturing trends are driven by manufacturers’ strong confidence in their ability to deliver high-quality products that earn repeat orders while delivering excellent customer experiences. Running Lean While Focusing On Keeping Margins Strong.

Lean Six Sigma

LeanCor

What is Lean Six Sigma Logistics? Lean Six Sigma is the combination of two methodologies that complement one another when applied to logistics and supply chain management. Lean Six Sigma Logistics: Lean and the Logistician. The impact of Lean on the logistician is significant. A common misconception of Lean philosophy is that it only finds application in manufacturing settings. Lean Six Sigma Logistics: Six Sigma and the Logistician.

What is Lean Manufacturing?

IQMS

Lean manufacturing is a series of techniques and workflows designed to help companies reduce costs, increase product quality while improving shop floor efficiency, all leading to improved profitability. How Lean Manufacturing Delivers Greater Visibility & Control.

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Lean Manufacturing Systems: How Mobility Empowers the New “Lean”

GlobalTranz

The use of lean manufacturing systems has become commonplace in modern manufacturing. Lean manufacturing refers to eliminating waste, reducing costs, and improving production with finite resources. As a result, many manufacturers have deployed extensive process review and analysis programs to move towards a higher level of lean manufacturing. Yet, mobility is poised to make the most dramatic impact on the concept and use of lean production.

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Inventory Management in Manufacturing Environment

LeanCor

Firms today are beginning to understand more and more that high levels of inventory aren’t just detrimental to costs but also for hiding other potential issues. Inventory management starts with lean buying and planning tactics as well as streamlined inventory management standard processes for material handling and planning. The beginning stage of inventory management doesn’t begin at the dock door rather it begins with the supplier. By: David Sherman.

FAQ: Is Demand-Driven Manufacturing the Same Thing as Lean?

synchrono

Many of our customers don’t start out looking to implement Demand-Driven Manufacturing per se. Often, they’re focused on Lean Manufacturing or at least some element of it. However, at some point in the conversation, they will inevitably ask, “Is Demand-Driven Manufacturing the same thing as Lean Manufacturing?”. Demand-Driven Manufacturing isn’t synonymous with Lean or other related initiatives such as Theory of Constraints.

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Multi-echelon Inventory Optimization and Lean/Six Sigma

Supply Chain Action Blog

How Lean Thinking Helps. Lean principles are applied to drive out waste. One of the most predominant lean tools used for identifying waste is Value Stream Mapping which helps identify eight wastes, including overproduction, waiting, over-processing, unnecessary inventory, handling and transportation, defects, and underutilized talent. In inventory management, this often happens through a reduction of lead times and lot sizes.

Manufacturing ERP Plays a Key Role for Sustainability

QAD

While consumer products manufacturers previously led the way for sustainable manufacturing practices, a growing number of manufacturers in other sectors are treating sustainability as an important operational objective to increase global competitiveness.

Multi-echelon Inventory Optimization and Lean/Six Sigma

Supply Chain Action Blog

How Lean Thinking Helps. Lean principles are applied to drive out waste through a reduction of lead times, lot sizes, and activity that does not increase the value of the whole. Lean principles have been encapsulated by the five S’s, taken from the transliteration of five Japanese words, which, in turn, have been translated into English counterparts. Seiri (Sort) – sorting, i.e., proper arrangement of all items, storage, equipment, tools, inventory and traffic.

Applying Lean Principles to Supply Chain Planning

Logility

Today, Lean is a concept, a philosophy, a practice, and a set of tools all wrapped in one. For more than 50 years, organizations have invested time and money adopting the principles of Lean (while originated at Toyota Corporation for manufacturing operations, the principles of Lean have since spread to many types of businesses and functional areas). The two primary principles of Lean, Just in Time and Jidoka, are referred to as the pillars of the lean philosophy.

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Can Better Planning Make Manufacturing Disruption-proof?

USC Consulting Group

The planning and forecasting process has always been a vital part of manufacturing, but now, after a roller coaster of a year, it’s becoming clear to many in the industry that this process needs to be bulletproof — and in many cases, it isn’t. Inventory considerations.

Introducing Lean In Retail … Start in the Backroom!

Supply Chain Game Changer

Check out 10 Signs You Should Reboot Your Lean Program! I decided that I would introduce Lean process improvement techniques to this company. I came from a Manufacturing, Operations and Supply Chain background so I spent a career surrounded by the application of Lean methodologies. However when I started the discussion around deploying Lean at this Retailer virtually everyone had no knowledge of what Lean was. Our Lean journey had begun.

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4 Supply Chain Areas to Examine in the Face of Disruption

QAD

Increasingly, we see manufacturers placing less emphasis on cost savings and more importance on supply chain adaptability, risk management and speed. The following are four key areas that can help manufacturers mitigate supply chain risks and build adaptability for future shocks. .

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Supply Chain Shifts From Lean Model

AB&R

With the supply chain’s lean model, many retailers were not able to respond to the sudden changes in demand. The study also predicts more demand as a result of shifting manufacturing locations to on-shore or near-shore. The last few months have put the supply chain to the test.

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