Lean Manufacturing - Business Plan Example

The idle time is too high and not permissible in any way. With the supply coming in weekly, the issue of each process should be regulated. Movements both within the section and between sections must be speeded up by the use of trolleys, installation of conveyors, and use of fork-lifts, wherever suitable. This must be identified and put in place as a top priority.At the moment we are paying a lot of wages plus overtime to workers for doing nothing. With such heavy idle time as against so little productive time, we need to cut down one shift altogether and move to a regime of controlled efforts and by using Pull methods of Just in Time system of inventory.

ERP software plays a vital role in the success of a Lean manufacturing setup. Nothing will be gained by just designing a superb system and by laying down rules and parameters. A well-understood, well-defined, and easy to follow the implementation plan must be prepared. This is to be done with active assistance from the solution providers.The Implementation Team along with the Company designated resources must first carry out a joint Systems Requirement Study (SRS). This SRS must consider all points raised in the strategy above and identify the areas of data entry points.

It is these areas that have to be carefully monitored to see that accurate data is available. With accurate data available, the company can take corrective action based on actual information. This will go a long way in bringing down wastages and eliminating downtime and idle time.A productive maintenance plan is to be drawn to ensure that downtime is brought down to zero levels with accurately planned maintenance schedules prepared in advance. Spares are to be procured for such programs well before time.