How to Implement Lean Production

thanks

Are you familiar with Statistical Process Control?

a little, what does it do with spc.?

Quality 3rd Edition ISBN: 0130419648 by Donna C.S. Summers

This book introduces fundamental quality concepts of statistical process control and the application of these concepts to issues arising in industry. This book covers all aspects of quality from the basics—identifying quality, the evolution of quality, quality advocates—to advanced More... topics such as reliability, quality costs, and product liability. For professionals interested in a book on quality that emphasizes the understanding, use, and interpretation of statistical process control principles, concepts, and results throughout the problem-solving process.

Make direct contact with any organisation currently supplying automotive industry. Even though there is a slump in business, they have been working on this for years.

You are hinting at the right observations though. The change necessary is at a personal level and must be part of EVERY employees understanding of the business.

It took us 5 years before we felt we could describe ourselves as "on the path to true lean" and we are still progressing (continuous improvement) twelve years later.

It's a process that nevere ends.

True continuous improvement has an end, it's called perfection, otherwise should be called "depicable improvement".

Yahlasit

I don't care about Toyota's filosphy, on an ever changing market you need to keep inventory to make quick changes to your production as required by demand.

Yahlasit

TIANSYV,

Your kaizen approach is appreciated highly.

People set to a routine job, have the feeling that, what they do is best, and believe that further changes are useless and are prone to mind set levels. The following tips can be tried.

*If the improvement suggestions inside the work premises don"t work, take the group for informal outing, create a free atmosphere to mutually discuss on the wastage issue.

*Inspire the team by taking them to visit places with good practices and ask them to interact and take tips to follow. Show videos if possible.

*In a company, some co operative teams will be there. Motivate them to perform for reduced wastage and demonstrate to others. Convince them with facts and figures and possible rewards so as to inspire. You got to show and demonstrate workable ways proven and convincing to you.

Convince,inspire and motivate and no rules and instructions work with experienced workmen. Be specific and perseverant.

Best Wishes.

very useful, thanks

Meaning no disrespect to the other posters, You are describing the need to create a major cultural change.

As a former plant manager, metallurgist, and corporate director, I would give you the following advice:

"You must become the change you wish to see happen."

"the biggest deterence to excellence is good."

If you lead and people see the demonstrated benefits, they will follow. If you and the system accept "good" you will never get excellence.

I am not familiar with the sources of the above quotes, but they are not original to me.

milo

I agree with Rangasamy, It needs to start at the top. If managemente does not want to change nothing will change.

5S is a good start, Improved housekeeping, removing items not required etc. As you are doing the production area include offices and desks.

Makes a huge difference.

All too often, people and especially management focus on the tools associated with "lean" (Like 5s, KanBan, JIT processing, ... and the list goes on) while not understanding the true methodology of "lean".

Bad experiences (like inability to react in time for contract opportunities) are not an outcome of "lean", but rather an outcome of using some of the tools in isolation and not understanding the total concept. (For instance, stock reduction without understanding your own reaction time can often lead to missed deliveries. The way to achieve stock reduction is to cause change to your reaction time so that you can then cope with having less inventory, not the other way around.)

However, it it an EXCELLENT idea to have those programs in place as the tools/skills that people will gain from that training will then come together in a proper lean implementation program.

Government owned is not an obstacle to lean, only another challenge. Some of the best lean companies in the world are larger (in financial terms) than some countries. In fact, being associated with government could be an advantage in that strategic decisions can be endorsed and not overturned by a new manager who may not fully understand what is in place.

Good luck in your adventure.