Lean Cell Systems and Plant Flow – Fast Production with Lower Costs
As manufacturers, we’re always looking for ways to make things work faster, cheaper, and simpler. Often the approach we take involves reassessing the production elements within the plant that impede system flow. In such an analysis we take stock of the operation as a whole in search of efficiencies in the parts. In short, to improve productivity and quickly respond to changing customer demands, we try to make the most of the resources available in our plant. In doing so, the modern manufacturer strives for total enterprise resource planning (ERP) that ensures all elements of the plant are in sync with each other. In the evolution of ERP as a manufacturing concept, the idea of workplace management as the locus of greatest efficiency gains has come to the fore.
While pull production techniques certainly strive to achieve just-in-time (JIT) manufacturing modes, efficiencies that could be gained in other plant operations are sometimes lost in costly setups and indirect labor costs associated with non-productive shop time. To overcome these negative aspects, the lean cells it was developed to take advantage of the production of repetitive units and the physical space of the plant. Based on sensible ergonomic principles, in the lean cell, operators work very close to each other, so close that they can simply pass units of parts. In the classic lean work cell, an ERP operation can maximize production efficiencies through some of the most basic lean principles:
- Continuous flow: By using shadow boards for tools and delivering material to the cell prior to assembly, the Lean Work Center eliminates most non-value-added operator movement (i.e. overhead). In other words, the lean cell becomes a place of efficiency where a value added to value added operation is performed.
- Configuration and reconfiguration efficiencies: By isolating repetitive production processes in a single space, cell setup and reconfiguration costs and times are significantly reduced. This results in maximized changeover with minimized downtime in relatively uninterrupted plant flow.
- improved quality: With the opportunity for immediate feedback through quality inspection, the lean cell reduces waste and improves continuous improvement, a principle of lean manufacturing. Also, by using simple and efficient machines in the cell, replacement of malfunctioning devices is often quick and easy.
- JAT delivery: Parts not only arrive at the cell when they are needed, but the fast flow of one-piece (or small) batches from the lean cell means that pull output is maximized at every step along the system flow. Additionally, non-cyclical work is performed by support staff located outside of the cell. All of these factors help to eliminate both inventory and work in progress.
Ultimately, the proper use of a lean cell system in an ERP operation significantly reduces production cycle time. From receipt of the order by the order entry clerk to shipping finished goods out of the plant, production time is reduced and JIT production is improved. Additionally, with overhead costs minimized through ergonomic flow-through design, lean cell manufacturing improves the all-important bottom-line profit margin.