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    Lean - V-Agile: Gerry Brame Managing Director Powrmatic (& SFL) UK LTD

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    Saurabh Rai
    The document compares and contrasts lean, agile, and reverse lean manufacturing approaches. Lean focuses on reducing waste to improve quality, cost, and delivery for customers. Agile adds an emphasis on flexibility and responsiveness to market changes. Reverse lean prioritizes eliminating unevenness and overburdening before targeting specific wastes, with the goal of creating flow to improve throughput and inventory levels. Experts debate the true differences and relationships between lean and agile manufacturing. Successfully implementing any of these approaches can be very difficult for organizations.

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    Lean - V-Agile: Gerry Brame Managing Director Powrmatic (& SFL) UK LTD

    Uploaded by

    Saurabh Rai
    130 views16 pages
    The document compares and contrasts lean, agile, and reverse lean manufacturing approaches. Lean focuses on reducing waste to improve quality, cost, and delivery for customers. Agile adds an emphasis on flexibility and responsiveness to market changes. Reverse lean prioritizes eliminating unevenness and overburdening before targeting specific wastes, with the goal of creating flow to improve throughput and inventory levels. Experts debate the true differences and relationships between lean and agile manufacturing. Successfully implementing any of these approaches can be very difficult for organizations.

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    Beacon LeanvAgile

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    The document compares and contrasts lean, agile, and reverse lean manufacturing approaches. Lean focuses on reducing waste to improve quality, cost, and delivery for customers. Agile adds an emphasis on flexibility and responsiveness to market changes. Reverse lean prioritizes eliminating unevenness and overburdening before targeting specific wastes, with the goal of creating flow to improve throughput and inventory levels. Experts debate the true differences and relationships between lean and agile manufacturing. Successfully implementing any of these approaches can be very difficult for organizations.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    130 views16 pages

    Lean - V-Agile: Gerry Brame Managing Director Powrmatic (& SFL) UK LTD

    Uploaded by

    Saurabh Rai
    The document compares and contrasts lean, agile, and reverse lean manufacturing approaches. Lean focuses on reducing waste to improve quality, cost, and delivery for customers. Agile adds an emphasis on flexibility and responsiveness to market changes. Reverse lean prioritizes eliminating unevenness and overburdening before targeting specific wastes, with the goal of creating flow to improve throughput and inventory levels. Experts debate the true differences and relationships between lean and agile manufacturing. Successfully implementing any of these approaches can be very difficult for organizations.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 16

    Lean -v- Agile

    Gerry Brame Managing Director Powrmatic (& SFL) UK Ltd

    7th March 2007

    Definitions
    What is Lean? Lean = Q+C+D Quality Cost & Delivery So what could Agile possibly be? Agile = (Q+C+D)+F where F = Flexibility

    Who Promotes Lean?


    Toyota, Dell, Ford, Porsche, Wiremold, Samsung, Honda, P&0, Ryan Air, Rolls Royce, Boeing, Airbus, GSK, Becton Dickenson, Parker Hannafin, Rittal, Bardon, Toshiba, Pfizer, Bespak, Tesco, Easy Jet, NHS? Nissan, Hyundai, West Pharmaceuticals, Pall Corporation, Augusta Westland, etc etc

    Who Promotes Agile?


    The Agile Mfg Forum Cranfield School of Management Association of Manufacturing Excellence (AME) Iacocca Institute, PA. APICS Cusumano & Nobeoka Thinking Beyond Lean

    What is Lean
    Lean is a business philosophy that reduces the resources and time required to complete any process by eliminating waste and making value flow to the customer at the speed that the customer requires by applying the 5 Lean Principles

    What Does Lean Promote?


    Specify value from the point of view of the customer Identify the value stream Make the value Flow Pull according to customer demand Aim towards perfection
    Womack & Jones, 1996

    What is Valued?
    Reduced Safety Stocks. Reduced Order Sizes. Improved Communication. Flexibility. On Time Delivery. Quality Products, Service, Relationship. New Products and Technology. Cost Reduction.

    So What is Agile?
    Agile manufacturing is a term applied to an organization that has created the processes, tools, and training to enable it to respond quickly to customer needs and market changes while still controlling costs and quality. An enabling factor in becoming an agile manufacturer has been the development of manufacturing support technology that allows the marketers, the designers and the production personnel to share a common database of parts and products, to share data on production capacities and problems.
    Wikipediea

    Key Agility Attributess


    Goldman et al. suggest that Agility has four underlying components: delivering value to the customer; being ready for change; valuing human knowledge and skills; forming virtual partnerships.

    The first three of these are also attributes of lean manufacturing.


    L. Goldman, R.L. Nagel and K Preiss, Agile Competitors and Virtual Organizations - Strategies for Enriching the Customer

    So again, what is agile?

    Technology Planning

    System Modularity

    Lean Enterprise
    Organisation Environment Logistics Customer Service

    The Agile Enterprise

    What Does Agile Promote


    Postponement - Benetton Virtuality Dell Commonality Software Boeing Compatability equipment- VW Modularity VW Mexico

    Views on Agile
    98% the same as lean with the addition of Postponement J Bicheno Big Marketing Trick by Cranfield University Darrell Mann Not a subject, still a concept Professor P Hines Lean repackaged but not endorsed by Toyota C Morse GSK Conceptually inept without a effective Lean base T Hankin Honda

    Reverse Lean !
    What is it ? Flow not Tools What does it achieve ? Instant T, I, OE improvements Has anyone ever done it ? Not Documented; but Alcan, Otukumpu, Powrmatic !

    Flaws of a Traditional Lean Implementation


    Focus misdirected; waste (Muda) not Operating Expense!! Ignores product Throughput time. Minimal attention paid to total Inventory. Total internal focus, isolation from Customer Demand & Expectation. Random Muda reductions cannot drop through diluting confidence in Lean concepts (loosing faith). 5S activities require too much time & effort to be effective & sustainable, plus no tangible benefits to the bottom line. Tools such as SMED become miss-understood, Capacity not Flexibility and miss applied ie;- Implementing SMED to non bottleneck processs. Tools are Tools not objectives or Goals.

    Reverse Lean
    WHY REVERSE? Massively more effective than the traditional Western approach to Lean Implementation. More replicable of original Japanese disciplines of Lean Implementation Create Flow 1st, Then use tools to Maintain Flow & to Organise for Flow WHY IS IT REVERSE? Re-Prioritisation; 1/ Mura (unevenness of operations). 2/ Muri (overburdening of equipment and people). 3/ Muda (waste).

    Lean, Agile or Reverse Lean


    No right answer All are very difficult & expensive >80% of all implementations fail Nobody is Lean. Toyota & Honda leading (Porsche) Chosen to suit specific need; - Competition, Crisis, Survival, Cash or Growth.

    But do one !

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