Validity and Reliability of Lean Manufacturing Frameworks, Research Paper Example

Introduction

This paper is based on the findings of the article that is related to the topic of Quality management subject. The article selected for this research is named ‘Design of Job under Lean Manufacturing and how it can enhance the quality of work life’. The article selected is a peer reviewed and a scholarly article and is published in the International Journal in the year 2015. This article specifically talks about the Lean manufacturing system and how it was adopted. The article also explains through various examples the impacts of the Lean manufacturing system on the manufacturing process specially the ‘Automobile Production’. Lean methodology was developed after World War II in Japan and then it spread in the developed world.  Japanese scientists took into account the conceptual foundations of scientific management developed at the turn of the 20^th centuries (Herzog & Tonchia, 2014).  The concept of Lean Manufacturing was first implemented by the Japanese company involved in the manufacturing of quality automobiles i.e. ‘Toyota Motor Corporation’ (Liker & Convis, 2012). The success of Toyota is because of the enhancement in its total quality management processes and this article will help in finding the benefits from the Lean manufacturing process.

Summary and Findings from the article

Lean manufacturing is now widely recognized as the most efficient, reliable and cost-effective way of companies to overcome the crisis and improve competitiveness. This method allow without significant capital expenditures to increase productivity, improve the quality of products or services, reduce costs and cycle time (Herzog & Tonchia, 2014). Lean production is an innovative approach to management and quality management which includes optimization of production processes, improve product quality, and reduce costs of different origin.  It is important to note that in recent years there are two closely related trends in economic development. Globalization currently covers not only the traditional markets of goods, technology, capital and labor but also control systems, support for innovation, human capital development (Cullinane Et al., 2014).  This regionalization is the desire of national economies to develop their own competitive advantage. Currently, the practice of enterprise management has developed a list of ways to improve performance, including reduced costs, reforming the organizational structure, optimization of employment, stimulating investment activity (Cullinane Et al., 2014).  A new level of production efficiency to achieve stability of the financial and economic situation of businesses as well as bringing qualitative and cost characteristics of products to a level competitive within the single market space. This can be achieved through the implementation of enterprise regional industrial complex tools and principles of Lean Manufacturing (Herzog & Tonchia, 2014).

One important aspect of the concept of lean production is the Kaizen principles of TQM. This is an in-depth analysis of the current situation to find the root causes of problems.  Lean Manufacturing involves search for the causes that are essential for the development of corrective and preventive actions for management decision-making, the establishment of new production sites, and so on. In this context it becomes especially urgent implementation of lean manufacturing processes (Cullinane Et al., 2014).   Lean Manufacturing is one of the new trends in the development of management, which is the next stage of penetration of Japanese and Western business culture to the U.S market.  The concept of lean manufacturing is improving the efficiency of production, by identifying and removing the hidden unproductive losses of the company with the help of special tools and techniques.  Traditionally losses refers to the processes that do not create additional value to customers.  Taiichi Oto (founder of the production system of Toyota) offered to provide seven types of losses;

1. Losses due to overproduction (excess production)
2. Loss of time due to the expectation (Cullinane Et al., 2014).
3. Unnecessary loss during transport
4. Losses due to the extra processing steps
5. Losses due to excess reserves
6. Losses due to unnecessary displacement
7. Losses due to the release of defective products (Cullinane Et al., 2014).

The implementation of lean manufacturing tools begins with bringing order and demonstrate the inconveniences caused by various factors.  For it is necessary to introduce the concept of 5S, which consists of 5 steps: sorting, self-organization, the contents workplace clean, and standardization workplace improvement.  Using this concept, a positive effect on safety, productivity and quality of products (Cullinane Et al., 2014).  The speed of operation is determined by the product manufacturing cycle time.  Reducing cycle time can reduce the cost of production for the company, which has manufactured and the cost to the consumer.  One of the methods to reduce the cycle time is Just in Time (JIT). If materials for the manufacture of products are provided only when necessary, the loss in the production process are reduced to a minimum.

The next step in the implementation of the concept of lean manufacturing is the method of Kaizen which means continuous improvement.  Kaizen system is based on a phased approach. It involves first an analysis of individual elements of the production process and then suggests ways to improve these elements (Herzog & Tonchia, 2014).  Lean production is permeated with the idea of Kaizen or continuous improvement are small, gradual and successive changes undertaken constantly and have a positive impact on overall production. The size of the production and purchase a kit of parts is one of the main standards in the organization of production processes and product delivery just in time (Cullinane Et al., 2014).  In practice, it is selected depending on the size of the order: the small volume of orders processed batch size parts can be ordered to take an equal number of them (Liker & Convis, 2012). Large orders and deliveries to the warehouse the entire volume is usually divided into several parties gear efficiency loading equipment, production area and working area.

Conclusion

To sum up, there is a need to develop lean production as it is particularly important in the transition of the world economy to an innovative way of development.  Knowledge economy and new management technologies are the only way to ensure the stable development of our country (Liker & Convis, 2012).   The proposed measures for the development of lean manufacturing implementation will provide potential industrial complex, achieving a new level of production, the formation of goodwill companies as manufacturers of products conforming to world standards (Herzog & Tonchia, 2014). As a consequence, this will increase the investment attractiveness of the region and expanding its presence in the market.

References

Cullinane, S. J., Bosak, J., Flood, P. C., & Demerouti, E. (2014). Job design under lean manufacturing and the quality of working life: a job demands and resources perspective. The International Journal of Human Resource Management, 25(21), 2996-3015.

Herzog, N. V., & Tonchia, S. (2014). An Instrument for Measuring the Degree of Lean Implementation in Manufacturing. Strojniški vestnik-Journal of Mechanical Engineering, 60(12), 797-803.

Jasti, N. V. K., & Kodali, R. (2014). Validity and reliability of lean manufacturing frameworks. International Journal of Lean Six Sigma.

Liker, J. K., & Convis, G. L. (2012). The Toyota way to lean leadership: achieving and sustaining excellence through leadership development. McGraw-Hill.