Analysis of Cellular, Kanban Approaches - Coursework Example

ENGINEERING THE LEAN ENTERPRISE Analysis of Cellular Approach Cellular concept introduced by Ralph is process-based and the workers are performing variety of tasks using dissimilar machines and equipment in the work area while the Joe's Approach is operational-based wherein workers perform one repetitive step in the process while the work areas are structured around similar machines and equipment. Based on research, Cellular Approach is somehow related to the philosophy of continual improvement of Keizen wherein it implies that in terms of time required, resources, product quality as well as other significant aspects that are related to the progress, it can continually be evaluated as well as improved. This is the philosophy of continual improvement. Kaizen do not only limit its concern for improvement of the manufacturing systems only but also the managers and workers in a workplace. To process changes for quantum improvement in performance, a team plans, as well as implements and works. Planning and Control Joe states, that ``Planning and Control are the lifeblood of manufacturing''. A Do you agree with this? How does Joe define planning and control? Can you have a good plan and maintain control without a good process in place? Why or why not? Planning should focus on goals and that there should always be the determination to achieve them. Planning and Control Yes, I agree that planning and control are lifeblood of manufacturing. Joe defines planning as focused on goals and that there should always be the determination to make these happen. Control goes with proper planning. No, one can not have a good plan and control in the absence of a good process because the main goal is set basically during planning period and as you pursue with it, control should be done along with an appropriate process. Significant Points Ralph is trying to explain and illustrates the idea of dealing with long process in planning and manufacturing. This means that the longer the process, the complicated it would be in terms of problems and conflicts encountered during the process procedure. There will be a need for more human resources that would mean dealing with more errors that will be addressed and should be resolved. This requires good supervisory techniques, managers and a solid manpower. No, we cannot possibly achieve that ideal state without the significant things in the previous pages of the book because the simple philosophies presented will give the reader deeper understanding of the main purpose of the authors. There are concepts that are discussed in this part that are very significant in the planning and control of manufacturing process. Lean production is a flexible method that pulls product through the system in a timely manner that enables fast shipping of the product. To make the manufacturing process more efficient, the product design is constantly improved. The resources used should also be maximized to increase customers' satisfaction. All stakeholders are expected to get quality on products and this would happen if there would also be cooperation, simplification, and coordination. Kanban Approach On the part of Joe, it is good to take advantage of technology especially in the business world where file keeping or even ordering are done systematically and easily through the computer tracking. Programming is still managed by human encoders. This could be the point of Ralph where data keeping and transaction are still safe and sure by human resources which he called the Kanban. A Japanese approach that is used in order to ensure that there is a continuous supply of the inventory or the product as well as the signaling device which gives instruction for production or the conveyance of items in a pull system is called Kaban approach. This is designed to support the JIT philosophy. It also indicates a time to replenish stock and possibly reorder. Nothing is wrong with computer, using both Kanban and computer tracking program would mean a big difference. JIT Philosophy Just In Time (JIT) is a guiding philosophy for manufacturing developed by Taiichi Ohno of Toyota which reduces inventory, minimizes waste and responds to customers. This advocates a lean approach to production and uses many tools to achieve the overall goal. Originally, JIT intended to perfect the system of the Japanese manufacturing companies in 1970s. Key benefits can be taken of this philosophy such as low inventory, low wastage, high quality production and high customer responsiveness. Similar to Line Balancing, in order to assemble a product in mass or series production on an assembly line among a set of work stations, it is not just a tool which consists of distributing work required. There is a difference between push and pull systems. The customer does not request the product to be developed in a pushed system. Rather, the product is being ``pushed at'' by promotion while on a pull system, the consumer requests the product and ``pulls'' it by delivery basis. Terms Defined ”Andon” is a tool of visual management wherein light are placed on machines or production lines in order to indicate operation status which is commonly color-coded. It is commonly color-coded green for normal operations, yellow for changeover or planned maintenance and red for abnormal, machine down. In addition to that it is often combined with an audible signal which includes music or alarm. The word “Andon” originates from a Japanese word which means “lamp.” (Kaizen Glossary, 2007). ”Jidoka” refers to the practice of stopping the entire line or process when something goes amiss. This could be applied to manned operations for continuous improvement. ”Nagara” means doing something while doing something else. In order to prevent a defect throughout the system or progress, the device that should be used is Poke-yoke wherein it is used as mistake proofing or procedure. A process which allows a person to reduce time to change a production process over for making one part or product to another part or product is called the “SMED or Single Minute Exchange of Dies.” It takes less than ten minutes. A highly successful manufacturing technique is the 5s, which is used to promote clean organized as well as disciplined working environments, which is more efficient and it provide the foundation for more advance techniques. Discussion of the book written by William B. Miller and Vicki L. Schenk The basics on the way to do and understand things easier with an advanced Lean manufacturing approach was explained in this fable-based book made by William Miller and Vicki Schenk. This encouraged the reader to believe that better results are achieved by good planning and control. The basic principles of customers such as high quality, low cost, on-time business management from design to delivery are fully explained in the form of entertaining stories of a weekend home improvement project. This book provides clear concepts as well as techniques which are applicable to the 21st century business management. How to forge a strategy for the future is illustrated in the book, wherein it will lead to understanding personal as the professional achievement. Readers easily grasped the purpose of the authors with the ideas emphasized by chapters. It is an illustrative story that started and ended every chapter with a phrase that captures the main idea. How to do things simply, with high quality, utilizing effective methods that prevent mistakes are explained in the book and it shows how to get people involved with their own work. In addition to that, it shows how to keep cost low as well as how to do things rapidly. All important strategies as well as tactics of the world class manufacturing are conveyed in the book. This book is all about management strategy, to sight examples topics such as how to run the business, how to communicate in a way that everybody in a business will understand and buy into are included. It also shows how to deploy the strategies into specific world class management tactics and complete as well as clear descriptions of all the key world class management tactics are included in the book. Included also in the book are the “Ten Commandments of Manufacturing Excellence” which combine the philosophy as well as techniques of Lean Thinking, Toyota Production System, TQM as well as many other programs in to ten easy to implement and use steps. These mentioned ideas are significant but reading all the contents of the book will sure make the difference. Part of these book are interesting Japanese terms as well as concepts which includes ``Kanban,'' ``kaizen,'' ``nagara,'' ``poka-yoke,'' ``jidoka,'' and ``andon.'' The phases of manufacturing plant-planning, training, presentation, purchasing, manufacturing, inspection as well as rework were also discussed in the book. The inclusion of the Ten Commandments of Manufacturing Excellence focused on the philosophy and Techniques of Lean Thinking where easy to use and implement steps where included. This book also provides an annotated reading list as well as a comprehensive glossary which contains a lot of Japanese words as well as concepts along with some American terms which make up the Production System of Toyota. Reference Kaizen, Glossary. (2007). Gemba Research LLC. Miller, WB. and Schenk, VL. (2004). All I Need to Know About Manufacturing I Learned in Joe’s Garage. Bayrock Press. Revised Edition. Weston, FC T. Jr., A Simulation of Shop Floor Line Balancing and JIT Employing TOC Principles. Colorado State University: DBA Computer Information Systems Department Read More