FAQs
What is Lean Enterprise?
Lean Manufacturing describes a concept of business operation that uses less human effort, capital investment, floor space, materials, and time in all aspects of production. A team with the concepts and tools for Lean Manufacturing can improve the bottom line of any manufacturing operation.
How does Lean differ from traditional manufacturing?
While traditional manufacturing philosophies stress high utilization of machinery and manpower with little concern for cycle time or manufacturing waste, the Lean Manufacturing production philosophy focuses on creating greater production efficiencies through maximizing value-added activities, while minimizing waste. While traditional U.S. manufacturing is rooted in "Just-In-Case" (JIC) philosophies, Lean Manufacturing is evolved from "Just-In-Time" (JIT) principles.
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What are the benefits of implementing Lean?
Typical benefits include:
Productivity improvements of 10-30%
Up to 90% reduction in work-in-progress 50% increase of space utilization
85% improved quality
Up to 90% reduction in lead times
Who are NBDC's Lean Enterprise consultants and instructors?
NBDC Lean Enterprise consultants and instructors are NIST/MEP certified and share over 110 combined years of industrial experience. Click on a name for business background.
Renee Held, BS, NIST/MEP Lean Certification
Martin Kostecki, BS, MS Industrial Aministration, CBM #0383, NIST/MEP Certification
Roger McCullough, BS, MS Biology, MBA, NIST/MEP Lean Certification
Gisele Olney, BS, MS Information Systems, CLBM, LEI VSM, NIST/MEP Lean Certification
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What is MEP?
MEP is a nationwide network of not-for-profit Centers in over 400 locations nationwide, whose sole purpose is to provide small and medium-sized manufacturers with the help they need to succeed. The Centers, serving all 50 States, and Puerto Rico, are linked together through the Department of Commerce’s National Institute of Standards and Technology. That makes it possible for even the smallest firms to tap into the expertise of knowledgeable manufacturing and business specialists all over the U.S. These are people who have had experience on manufacturing floors and in plant operations.
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What are the primary benefits of creating a visual workplace?
Fewer defects and higher quality
Fewer equipment breakdowns and better availability
Efficient and effective navigation and organization; choices are made clear
Saves time and cost while making workplace easier to maintain
Improves production schedules, fewer delays
Simpler inventories
Motion and waste reductions
Fewer injuries as a result of better visibility and organization
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What are the benefits of implementing Value Stream Mapping?
A value stream map is a compilation of all the actions required to bring a product from raw material to delivery to the customer. Mapping the whole production process allows the lean enterprise to identify and eliminate any activity that does not add value to the final product. Mapping improves production by:
Identifying the sources of waste
Developing a common language about process
Linking information and process
Prioritizing actions.
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What are the primary benefits of implementing Total Production Maintenance (TPM)?
Implementing a TPM program reduces make-ready wastes, defective product, and startup losses and also helps eliminate productivity interruptions. Benefits include:
Unplanned downtime Down 50-60%
Breakdown costs Down 70-80%
Spare parts costs Down 15-30%
Product defects Down 85-90%
Lead times Down 50-75%
On time deliveries Up 50-95%
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What are the primary benefits of implementing Quick Changeover/Setup Reduction?
Shorter lead time
Less material waste
Fewer defects
Less inventory
Lower space requirements
Higher productivity
Greater flexibility
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What are the primary benefits of implementing Pull/Kanban?
Achieves shop floor control of inventory and production scheduling without the aid of materials requirements planning (MRP)
Links producing and consuming processes while often reducing WIP by 50%.
Increases productivity
Reduces inventory and floor space
Dramatically improves process lead times
Sets up point-of-use material storage and better interfaces with planning systems
Sets lot sizes with capacity rather than economic order quantity theory
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What are the primary benefits of implementing Cellular/Flow Manufacturing?
WIP reduction of up to 90%
Space utilization of up to 70%
Lead time reduction of up to 95%
Productivity improvement of 10 to 40%
Quality improvement of 25-75%
Enhanced teamwork and communication
Enhanced flexibility and visibility
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