Lean manufacturing reduces errors, increases efficiency and minimizes waste. Planning methods that help achieve lean manufacturing keep their focus on each stage of the production process and improve performance by streamlining activities. A structured approach to planning for a lean manufacturing environment helps generate high-quality products at a pace that matches market demand.
Rate of Production
Lean manufacturing avoids overproduction by using planning methods that accurately estimate sales and adjust the production rate accordingly. Ideally the company produces an item just as a customer purchases one. Such planning requires a rapid updating of sales figures and a flexible production schedule. Using this method means you have to distribute your sales forecasts and sales reports directly to the employees responsible for production scheduling so they can make the necessary adjustments.
A key element of lean manufacturing is a low error rate. Since there is no slack in the rate of production, it becomes important that each completed item has the required quality level. Planning for a low error rate gives responsibility for the correct completion of each stage of the manufacturing process to employees at the working level. This method assumes that the employees carrying out the work best know what can go wrong and how to prevent errors. You have to identify competent and responsible employees in production and make sure they have the training and instructions to allow them to isolate and reduce production errors.
The production line becomes more efficient when you apply the planning methods of lean manufacturing. You examine your operations and identify waiting times, time spent moving material and time spent in a production process. For each activity, especially for time spent waiting and moving material, you ask how the workers can reduce the time spent. They can often eliminate many waiting times entirely and may be able to reduce the amount of movement that takes place. While you can usually save time spent on some of the production steps, the method places the most emphasis on time spent moving material and waiting since these activities are not productive.
When you have an efficient manufacturing line with production that matches sales, it doesn't make sense to keep a lot of inventory on hand. Lean manufacturing uses just-in-time methods to keep inventory at a minimum. Your planning has to reach to suppliers to ensure they are aware of production scheduling and can deliver the required amounts of materials and components just as the production line needs them. Using the just-in-time method allows you to reduce the space needed for storage and the amount of cash tied up in inventory.
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