Can the lean provide chain get too lean? That is a scorching subject now that Toyota is struggling security and high quality woes probably associated to its provide chain. Whereas the lean manufacturing pioneer grapples with the fallout and restoration from “unintended acceleration” and different points, high-tech producers would do nicely to view the troubles at Toyota as a cautionary story in lean Supply chain risk analytics practices. Whatever the ultimate verdict on Toyota, the availability chain can, certainly, get too lean. As a veteran of a number of lean implementations within the high-tech trade, I’ve bought a number of recommendations for staying on the best facet of the lean line.
Do not dismiss Toyota. Individuals who say that Toyota has tousled due to lean are usually not clear about Toyota’s historical past or the actual root explanation for their issues. Toyota has an incredible provide chain in addition to the unique and finest, long-term implementation of lean manufacturing. In reality, the Toyota Manufacturing System that the corporate began to develop within the 1950s is the unique blueprint for lean manufacturing. The actual root explanation for their issues: the change of technique within the 1990s to grow to be the biggest automotive producer on the planet. Backside line, they tried to develop too quick!
Extra humbling for U.S. automakers, Toyota drew closely on the works of W. Edwards Deming, an American. After Toyota efficiently applied lean, the U.S. automakers adopted lean manufacturing. Backside line, no matter classes Toyota might be taught from any provide chain errors will definitely be price finding out.
Take note of the main points. Many lean implementations are executed sub-optimally. They might look good due to the emphasis on the seen. Folks take note of establishing visible controls, fool-proofing meeting strains, laying out manufacturing facility flooring and “strolling the Gemba” – all of that are nice. You must do these issues. However that is solely half the job.
The opposite half of the job entails the unseen. Using analytics and statistics to grasp, management after which enhance processes. Whether or not it is measuring variability of output from a CNC machine or understanding demand patterns, it’s a must to be moderately subtle in the best way that you just apply these methods in a lean atmosphere. You’ve to have the ability to acquire and interpret knowledge accurately to do issues proper, e.g., know what your stock degree must be to offer a desired service degree or know when a result’s exterior a management restrict. When you do not take note of the main points – or you do not know what you are doing with the main points – issues can (and can) go incorrect.
Reinterpret stock. Lean producers view stock as a crucial evil. Why? As a result of as a producing self-discipline, lean encourages the elimination of waste, which incorporates stock. In the meantime, Wall Avenue takes a unfavourable view of stock in the case of company valuation. To Wall Avenue, stock is a non-performing or under-performing asset.