Lean Production - Term Paper Example

Lean Production Lean philosophy has been derived from the Japanese word ‘Kaizen’ (Thompson,pp.3) that endures continuous and endless improvement not only in the manufacturing and in assembly line, but imposing the principle in every business and industry. The vision of lean production was researched by Sakichi Toyoda in the 18th century that was later revised and implemented in the Toyota Group, which is also known as the ‘ Toyota Production System’. The significance of Lean production lies in the philosophy of lean thinking i.e. minimal defects and variety of output with least input.

The important aspect is ‘half ‘that symbolizes reduction by human power, investment, manufacturing and engineering hours (Black, pp. 6-15). It forms the systematic approach on cost reduction, quality, time management, delivery aspects, safety, and morale. It also models the ongoing customer pull and continuous flow of improvement. Gallus group also justified the lean production by eliminating 50% inefficiencies in their processes and saving on millions of Euros per year by a limited outlay.

An important aspect of the lean philosophy is ‘Elimination of Waste’. It works on the excellent epitome of Zero’s i.e. zero waste. It features zeros in “defects, over production, waiting or lead-time, inventory, inappropriate processing, transportation movement” (Creative Class, pp. 25-29). The re –engineering not only implies in business process but also to people’s attitude, efficiency, and input. The JIT (Just in Time) will eliminate the inventory holding cost by pull production of ‘zero’ strategy.

The Toyota City is the best example of the just in time system that not only caters the main production but also its suppliers. The Japanese strategy of lean transplant was to bring an innovative approach to work practices such as work force, apparent skills and knowledge, quality management etc. On the contrary, the US and North American manufacturers gave significance to the adoption of self-directed workers team. According to the traditionalist Taylor, work practices are more essential and effective when clustered altogether on a factory floor.

The mixed approach urges to invest in off job training of the workforce. The innovative approach focuses on adoption of best practices in and out of the plant. It is capital intensive but also has the best skilled workers specifically automotive plants. The key source of overall significant performance of any organization is the blend of innovative work approach and innovative business processes (Creative Class, pp. 29-30).   Work Cited Black, R Johnsons. Lean production: implementing a world-class system.

Industrial Press Inc., 2008. Thompson, Jim. Lean production: how to use the highly effective Japanese concept of Kaizen to improve your efficiency. Productive Publications, 1997. Creative Class. The Japanese Transplant in North America: Production, Organization, Location, and R&D. Creative Class Group, 2011. Retrieved on June 10, 2011: http://www.creativeclass.com/rfcgdb/articles/12%20Japanese_Transplants_in_North_America.pdf