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Lean Manufacturing as a Holistic Approach

The concepts of lean originated from Japanese culture where balance, harmony, discipline and group organisation are central themes – it is not enough to use one element, they are more effective when used all together. Similarly, in manufacturing the use of lean manufacturing beyond one department such as the plant floor that make a lean initiative more effective. 

Having an organisation wide lean initiative can be viewed as using all the different elements of lean. There are three different elements, these include:

1. The business value stream layer
2. The business environment layer; and the
3. Business strategies and tools layer

 

The Business Value Stream Layer

According to Womack and Jones 1996 definitions of the business value stream later, there are five main steps to achieving lean transition for organistions. These steps are the base layer to the holistic approach and it sets the tone for how organisation plan to serve its customers. The five steps are:

1. Defining value based on the customers point of view
2. Record the value streams for all processes serving internal and external customers
3. Make the activities flow efficiently
4. Respond to customer demand
5. Continuously improve the processes based on feedback

 

The Business Improvement Layer

The next layer is the business improvement layer which includes elements regarding improvement and enhancement. This includes six elements:

1. Eliminating waste
2. The Five S's (organising, cleaning, developing and sustaining work environment)
3. Visual Cues
4. Documented procedures and instructions
5. Error proofing
6. Six Sigma and lean quality 

The Business Strategy Layer

The top layer is the business strategy layer which includes specific applied methodoligies. It is used to monitor the business transitions which include: customer order placement, customer order production, customer order fulfilment, customer service order taking, and material receipt and insection.

 Once an organisation begins to embrace the lean philosophy, each department can realise the significant benefits. 

That is why Infor Enterprise Resource Planning Software can help you to apply all the different elements of lean to reduce your operational costs, eliminate waste, improve efficiency and adopt lean manufacturing processes in your organisation.

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