Concept Design - The Fourth Step Used by Our Lean Manufacturing Consultants

In any organisation with a typical function manufacturing architecture, where similar manufacturing processes are grouped together we use a seven step approach to establishing a Lean Manufacturing foundation and delivering breakthrough performance improvements for our clients:

1. Lean Manufacturing Diagnostic
2. Team Selection
3. Team Training
4. Lean Manufacturing Concept Design
5. Lean Manufacturing Detail Design
6. Lean Manufacturing Implementation
7. Post Implementation Audit

Benefits Using Lean Manufacturing Consultants

Reductions in direct costs of between 20-30% are typically possible, and lead times (and work in progress inventory) can be halved. This article examines the content of a typical "Concept Design" stage during a lean manufacturing programme.

Some of The Typical "Concept Design" Steps Taken by Our Lean Manufacturing Consultants

A typical "Concept Design" process used by our lean manufacturing consultants includes the following steps:-

1. Collect data required for cell definition:

• Product types
• Product volumes
• Manufacturing routes
• Market forecast
• Product Life-cycles

2. Using appropriate lean manufacturing tools and techniques, review options for a cellular manufacturing structure and select the most appropriate option for the business.

3. Identify a rough-sizing of the cells in terms of the equipment, plant and manpower, assuming nominal demands.

4. Specify appropriate operating principles e.g.:

• One man - one machine
• One man - multiple machines
• Nagare
• etc.

5. Specify where the cells should be and hence construct a top level factory plan showing material flows for the site.

6. Identify manufacturing support requirements and specify how they should be provided.

7. Construct aschematic of control systems required including:-

• interfaces with upstream "suppliers"
• interfaces with downstream "customers"
• between the designed cells

8. Identify measures of performance for each cell, based upon customer and business requirements.

9. Identify what action needs to be taken on an on-going continuous improvement basis and specify a mechanism that ensures they are made.

• machine reliability / planned and preventive maintenance
• machine / process capability

10. Review machine set-up times and identify areas where significant reductions would have a significant impact on the performane of the manufacturing system.

11. Construct a project plan for the detail design phase.

12. Undertake an appropriately detailed cost benefit analysis of the redesign.

13. Recommend quick hits (issues that can be picked up and solved off line).

Looking for Lean Manufacturing Consultants?

Executive Interims - Supply Chain Practice is a specialist provider of supply chain management consulting and interim management services. If you'd like to know more about what our Lean Manufacturing Consultants can do for your business, feel free to contact us.