Lean Manufacturing - A Solid Start But Not the Finish Line on the Factory Floor

Some factory floor managers are making the mistake of assuming that lean manufacturing is the end all be all of their factory floor control. Warehouse and Logistics News begs to differ with that logic in a recent article titled "Modular lean is the start not the end" [of factory floor oversight].

Today, many factory floor managers talk about implementing lean manufacturing with too little knowledge about the overall concept and goal. In trying to implement the process, many U.S. manufacturers have been disappointed by inadequate results, while others have found the process too disruptive. Still others believe they are adhering to the principles of lean manufacturing but lack the control to improve the process. Therefore, they may actually be costing themselves more money in the long run. That's not to say that lean manufacturing doesn't serve a purpose on the factory floor, however.

"Many of the most successful implementations of lean manufacturing involve production staff collaborating with engineers to identify and implement change on the shop floor," the article goes on to point out. It continues its praise of lean manufacturing's benefits in this way, "Another major area where introducing lean can help make significant improvements is with [factory floor] stock control. ... the storage equipment can be configured to the specific handling requirement and built to optimize the use of available space, not too much and not too little. In many instances, this can free space on the shop floor that can then be used for additional value-adding processes. The amount of inventory tied up as 'work in progress' is generally also minimized, which releases cash for use elsewhere in the business."

The implementation of a real-time data collection system that provides job tracking and factory floor control can assist shop floor managers in realizing all the advantages of lean manufacturing-plus a host of other desirable outcomes. A solid lean manufacturing strategy, one that is built upon a solid factory floor management system, goes beyond just-in-time approaches. It strives to reduce factory floor inventory through better communication about production processes and their inherent problems. By tapping into the knowledge of factory floor personnel, it makes their expertise part of the solution.

So what can factory floor managers do to move successfully toward lean manufacturing? One of the obvious but often overlooked tools is information from an electronic floor system. A factory floor information system can help manufacturers move forward with lean concepts of identifying problems, following the flow of parts, and measuring changeover times.

With information systems, factory floor processes and parts flow, sometimes referred to as a "current state map," are visibly tracked through production. This process flow is visible and available all day to all employees. As a result, improvement becomes a continuous, ongoing goal for both management and factory floor workers.

The bottom line is if companies want to have leaner production processes, they need to make sure they evaluate all the alternatives. It is important for factory floor managers to think creatively and use the information tools that are available to them creatively. That includes leveraging a real-time data collection system that provides job tracking and factory floor control.