All Lean Manufacturing questions

• Where to Start with Lean
  Good morning, David. This is Yogesh from Bangalore, India. I have joined a small shirt manufacturing company as an Industrial Engineer. We manufacture about 2,000 shirts per day for Peter England & Wrangler. We have approximately 340 employees. I just want to know what, where, and how to start to do things systematically here... P.S: I have no industrial experience as such in this field. This is my first job and also this is the first time that an Industrial Engineer is being appointed here in this firm.

• Starting a Lean Education
  How do we sustain lean in a contract manufacturing environment? I know people are the key issue. How do we go about doing it? Please recommend some good books or videos on this topic. Thanks,

• A Kanban Alternative
  We are in the process of defining a lean manufacturing system for an MTO industry. The key to this industry is that all the orders are unique items and are based on the customer specifications. How do we set up Kanbans for this industry? I have heard that other processes, e.g., CONWIP, can handle such a situation. Has the industry accepted the CONWIP philosophy?

• Applying Lean in the Garment Industry
  What are lean manufacturing's general concepts, especially in the garments industry?

• ISO Compliance
  We just initiated our lean journey and while it is all good, I am a little concerned about the Quality System requirements, (ISO) vs some of what we're doing to eliminate work orders, routings, material ID on individual parts and inspection/test status requirements. Is there a document/white paper that covers ISO compliance in a lean environment?

• Toyota Product System & Lean -- One in The Same?
  Is there a different between Toyota Production System(TPS) and Lean Manufacturing. Have they originated from the same place? Would you be explaining the history of both?

• A Dose of Lean Reality
  We are interested in kicking off a Lean implementation however not everyone is convinced that this is the right approach. I would be interested in a list of manufacturers that you know who may offer plant tours specifically highlighting their Lean efforts.

• Lean Scheduling
  Dear David, I have always believed in what lean manufacturing proposes, but my fear now is do we need ERP, MES and scheduling packages to complement lean to gain competitive advantage. These packages cost a lot and take substantial time to get everyone to buy in to. What do you think.

• Tapping ERP for Lean
  How would we use an ERP system to help us with our Lean/Level Production? We are currently using Fourth Shift (ERP), MTO and our lean/level production initiative is at at the infant stage. Thanks.

• CMMS Software Excellence
  What CMMS software is leading the manufacturing facilities in Maintenace Excellence programs. I would like some comments and recommendations on the four software products which I am reviewing: Indus Empac, MP2, Cworks, & Ivara. My application will be a enterprise based system in which information can be shared across multiple facilities. Thanks

• Counting the Beans With Lean
  We are in the process of converting to a lean manufacturing environment. I am responsible for the Cost Accounting and Cost Estimating areas and need to identify how we will be able to estimate our products in a lean environment. This will include estimating the material and labor for both end units and spare parts. We will not have any travelers and all of the labor will be charged to a few identified short accounts. There will be no way to track the labor to a specific part. Our products will be grouped under six value streams. All material will be expensed as soon as it comes into the plant. (Some items from non-certified suppliers will need to be inspected first). We are a defense contractor and have needed to supply very detailed estimates to our customers and government auditors in the past. We will still need to support our estimates for government audits and customer fact finds. I would appreciate any information or guidance that you can provide to me.

• Virtual Reality Check
  Can virtual reality techniques be used for a lean manufacturing system? Are there any projects recently done that relate these two areas. Best.

• Lean in Aerospace
  How long does it take for a large aerospace company to incorporate lean practices across the organisation. Thanks & Regards.

• Lean on the Cheap
  Sir, I have a non-specific question: Where can I obtain (with limited resources) project/thesis data in the area of lean manufacturing ( I don't have access to any industry data)? All I can get is educational material (past dissertations and access to library material). Awaiting your reply. Best regards,

• Lean Cuisine
  I would like to know the possibilities of applying lean principles to the food industry.

• Cleanliness & Orderliness Before Lean?
  I want to put a pull system in place with vendors as a first step toward lean because it will produce quick positive results and I am getting resistance from those who believe we should educate and install 5S first. I agree that neat & clean & orderly are important and we are that already. My objection is that the time & effort can be spent on installing the vendor pull system. Also I have never seen inventory go down or profit improve from sweeping the floor & improving the cleanlyness by 10% above the current level. What do you think?

• Lean = flow-based production?
  What is the difference between a Lean shop and a flow-based production environment? Aren't they essentially the same thing?

• The role of APS
  What is the role of Advanced Planning Systems in a lean shop?