Exact Hosted Lean Manufacturing Breakfast at CCSU

Exact Online hosted a breakfast discussion on “Why Lean Manufacturing is a Critical Differentiator for Small Manufacturers” and a hands-on demonstration of the technology behind lean manufacturing.

During the presentation, we discussed the phases of implementing a lean manufacturing program. Without oversimplifying, the lean journey involves three major steps, briefly described below:

Phase 1: Prepare to launch a lean program. Owners and key stakeholders must start by developing a three-year business plan that provides a roadmap and structure for their lean journey. You start by determining what your business is good at doing, what you want to improve and, most important, you must get all employees on board for what lies ahead.

Phase 2: Get started with the basics: develop part families, eliminate unnecessary parts and design the first lean cell (sets of machines that are grouped by the products or parts they produce). Simply put, you’re looking for parts that are similar in shape and geometry or that are produced using similar processes – this is one of the most important steps in the process. You may take 1000 parts and turn them into 30 part families. This step will enable you to eliminate unnecessary parts that can disrupt production and provide a roadmap for how you’ll create a more automated production flow. From here you’re ready to design the first cell, including the team, part family, machines, materials required, etc.

Phase 3: Build out the lean program. Using the results from the first cell as a blueprint, you’ll extend the model to other areas of the shop floor, starting with the next part family. Running each cell independently enables you to see which cells are profit centers and which are not. It also enables you to see waste, from overproduction that wastes materials to unnecessary employee waiting time and maintaining costly inventory that customers haven’t ordered.

Didn’t catch our interactive presentation last time at CCSU? Don’t worry - Exact will be holding events all through 2015. Look out for more!

Photo Credit: CCSU ITBD