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The Conventional Production System

The Conventional Production System

The main problem with conventional production systems is that they generate many forms of Muda (waste), which in turn, do not meet with the current strategic needs of companies moving towards Lean: quality, costs, and delivery. It can easily be seen how mudas are generated by the mass production system in the above illustration of a typical assembly line. Source: Vision-Lean Muda of waiting: a waiting employee does not create added value. Muda of transport: products transported from one place to another within the plant do not create added value. Muda of inventory: capital unnecessarily tied up, value destroyed. Muda of...
on July 17, 2017
Priority on the Line Side

Priority on the Line Side

Why give priority to productivity on the line side? The production line is the place where value is created and place with the highest labor density. The production line is the most expensive place in terms of plant investment, production costs, and labor costs. One of the golden rules of Lean Manufacturing is that the elimination of Muda must be must be prioritized to the point of added value, i.e. assembly points. Using Ecoflex as a catalyst, we can see how Mudas must be “moved” from the line to upstream processes, so that it can then be reduced and eliminated....
on July 12, 2017
Optimizing the Work Station

Optimizing the Work Station

One of the simplest improvements to Lean Manufacturing at the line side to increase productivity requires a modification of the packaging to a smaller size and optimizing how it’s delivered.  Implementing new Lean Manufacturing principles to the logistics of material flow eliminated Muda and improves can improve production considerably. By optimizing compressing the line side space, the most taxing Mudas for production are reduced: the Mudas caused by unnecessary motion and waiting. Below we see a conventional production system consisting of heavy stock being transported from warehouse racking to the production line in bulky containers with dangerous forklift traffic. Source:...
on July 05, 2017
Eliminating Muda with Ecoflex and IPS

Eliminating Muda with Ecoflex and IPS

It is no wonder why companies committed to Lean Manufacturing have adopted the Ecoflex system. Ecoflex provides the quickest method possible to get started and put ideas for continuous improvement into application easily and with simplicity. The versatility of the Ecoflex system can assist in introducing the Kaizen attitude through its ability to quickly configure and re-configure material handling solutions. Worldwide, the coated pipe and joint system is recognized as the industry standard tool for successfully introducing Lean Manufacturing into production environments. Operating against the pressures of ever-faster production cycles, it is essential that companies can adjust their material handling...
on June 28, 2017
Kaizen

Kaizen

The Kaizen attitude is the Lean Company’s driving force in the fight against muda. Kaizen refers to the philosophy or practice that focuses upon continuous improvement of processes in manufacturing. When applied to the workplace, Kaizen refers to activities that continually improve all functions, and involves all employees from the CEO to the assembly line workers. One of the first steps taken towards Lean Manufacturing is to implement teams (including operators) on the factory floor to help reduce waste. The Kaizen approach consists of making continual user-driven improvements to eliminate waste.  The incomparable flexibility of Ecoflex and the simplicity of the system...
on June 08, 2017
The Seven Mudas

The Seven Mudas

Lean Manufacturing is based on the principle of reducing waste. The importance on the elimination of these wastes is illustrated in the following figure. Through kaizen efforts, the elimination of waste helps companies move towards positive growth and progress towards Lean Manufacturing. In order to keep from relapsing, standardization of work prevents companies to reverting back to their old way.  The seven main types of Muda (waste) are: Transport (moving products that is not actually required to perform the process) Overproduction (production ahead of demand) Unnecessary Stock ie. Inventory (all components, work in process and finished product not being processed)...
on June 01, 2017

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