Shop Floor Improvements

Functional Area Conventional Manufacturing Lean Manufacturing Value Added
 
Workers
  • Managed by supervisors
  • Empowered to improve process
  • More satisfied workforce
 
  • Few Individual Responsibilities
  • High Individual Responsibilities
  • More challenged workforce
   
Scheduling
  • Push the production out the door
  • Pull required products through production
  • Increases throughput
  • Continuous flow
 
  • Tasks Production
  • Authorizes production
  • Prevents overproduction
 
  • Schedules independent of shop status
  • Pull dependent on shop status
  • Prevents obstacles from forming
 
  • Large variety schedule mix
  • Common design product groups
  • Reduced production turbulence
 
  • Mass volumes per product
  • Low volumes per product
  • Greater production flexibility
   
Quality
  • Focus is on defects
  • Focus is on errors
  • Prevention is better than rework
 
  • Will catch bad parts at final inspection
  • Inspected at "every" step
  • Defects stopped at source
  • Prevents batches of defects
 
  • Prevents escapes
  • Prevents defects
  • No value added to defects
   
Production Volume
  • Production based
  • Production strictly equals sales
  • Make only what's sold
  • No overproduction
 
  • Production "pushed" per forecasted need
  • Production "pulled" as needed
  • Lower finished product inventories
   
Production Mix
  • Single product at a time
  • All products evenly produced
  • Increased production flexibility
 
  • Larger batches are better
  • Smaller batches are better
  • Increased quality assurance
 
  • Wide range of products
  • One-at-a-time is best
  • Products grouped by commonality
  • Make to order is possible
  • Fewer set-ups/change-overs
   
Work Force Skills
  • Expert skills in broad range of functional tasks
  • Ultra expert in narrow range of tasks
  • Less skills training required
  • Narrow range allows perfection
 
  • Specialized workers
  • Flexible workers
  • Less costly workers
   
Response to Abnormalities
  • Use of buffers to smooth production turbulence
  • Stop production & fix problems
  • Near Zero defects
  • Lowers inventory costs
 
  • Keep production going at all costs
  • Stops the line until corrections made
  • Near Zero obsolescence costs
   
Equipment Set Ups
  • Large batches to reduce need
  • Ultra quick set up to increase flexibility
  • Quicker set-up/change-over
 
  • Reduced set-up frequency
  • Reduced set-up duration
  • Additional production flexibility
   
Continuous Improvement
  • Machine efficiency
  • Process improvement focused
  • Ties production processes together
 
  • Problem solving by experts
  • Problem solving by workers
  • Everyone's an Industrial Engineer
  • Immediate, sustainable corrective actions
   
Standardized Work
  • Control from above
  • Shop floor owns process
  • Current "Best" practices
  • Operators empowered to improve owned process
  • Always use Best practices
   
Equipment Maintenance
  • Repair when it breaks down
  • Prevent from breaking down
  • Inventory reduced
 
  • Live off large inventory while repairing
  • Operator does common service
  • Preventive maintenance required & enhanced
 
  • Numerous repairers waiting for machine to fail
  • Repairers focus on PM
  • Fewer repairers required