Disadvantages Of Lean Manufacturing

Manufacturing Based on Hansen Mowen, lean manufacturing is a method which designed to maximize customer value and eliminate waste. It is characterized by delivering the right product with the right quality (zero-defect), right quantity to customer, at the right time when the customer needs it and at lowest possible cost. Waste is defined from the customer’s view of any process or activity that has no added value to the final product or service provided. Value is defined as any action or activity that could be paid by the customer. Lean management engages everyone in the designing processes to continuously solve problems and improve performance. Lean manufacturing systems allow managers to eliminate waste, reduce costs, and become more efficient.

This could be happened because organization try to cover up for possible defects or because produce large batches could save more costs. This is a major flaw that occurs unknowingly with most manufactures. The key causes of overproduction are producing to a forecast, just-in-case production and unclear of customer needs, for example organization producing more parts than can be sold or have already been requested by customers. This waste can be solve by identify the quantity of raw material and the demand that required. The quantity of goods should be updated every time so work can be done in a better

This is the waste incurred by transporting unnecessary parts and materials around the plant facility. The cause of transportation waste are poor plant layout, producing forecast and also produce in large batch sizes. One way to reduce the amount of transport in production is by changing the layout of plant into production lines in which a product flows through the same workstation in the same order. The second option is the use of cellular manufacturing where production lines are built in a U-shape. Input and output of each workstation should all be on the same side to reduce distance between