Question

4. Explain the benefits of using lean manufacturing layout shown in figure 5(b) compared to the traditional layout given in figure 5(a). Figure 5(a) Figure 5(b)

Answer 1

Hi, thanks for the question.

The concept of lean manufacturing is particularly useful since it concentrates on maximizing productivity whilst minimizing wastes in the production process. Lean manufacturing systems were first introduced by Toyota and it was based on a customer demand-based production method.

In this method, the production only takes place when the customer demands the product. So it is a "pull" type system. This allows in keeping costs low, minimizing unnecessary wastes, smaller inventory, and overall tighter control on things.

Traditional manufacturing methods are those which work on a "push" mentality which means that the product will be kept in production even if the customer does not demand it. The traditional manufacturing methods work based on sales forecasts and marketing forecasts. Hence, the tendency to produce wastes and higher costs are involved in traditional production methods.

Another aspect of lean manufacturing is the process of continuous improvement or Kaizen. This involves the practices of improving the current process in order to maximize the productivity and outcome of a particular process. This allows room for changing and upgrading processes and making changes in the overall production process in order to accommodate and inculcate the suggested change in the overall production process. In traditional production, processes are seldom altered since the layout is laid based on the forecasts, and incorporation of changes mean changes in layout which lead to added costs and reduced productivity.

In the above example pictures, the 5(a) shows that the platform has been built for a single purpose only while the 5(b) shows several processes being performed on a single platform hence increasing the overall productivity. This type of system allows a reduction in production cycle time. The traditional production approach is based on people learning how to not make mistakes while lean manufacturing methods are designed to make the process so simple that they become fool-proof and immensely value-adding.

Hence, lean manufacturing systems are now more preferred as compared to traditional methods.