What can lean production do? What are the solutions for lean production?

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People have always advocated lean production, but many wonder what lean production can achieve What are the solutions for lean production? What can lean production do? I use the example of 2 production cycles to illustrate what lean manufacturing can achieve. Example 1: Suppose the company’s manager has received orders for 6,000 products. The average daily production capacity is 600 units, with 12 identical processing steps; there are no delays between these steps, and the production cycle time is 3 days. I wonder whether it is possible to complete all these orders through concentrated production over 12 days Answer: No. Why--because the production cycle time determines that it takes 3 days to go through all the steps for the first unit, after which production can proceed at a rate of 600 units per day. In other words, within 12 days, only 7 days are guaranteed, which amounts to 7 * 600 pieces = 4,000 pieces. The production cycle time results in a significant delay in the delivery of your first batch of orders; the key factors contributing to this delay are the production cycle time, the pace of production, and the total volume of orders required. Example 2: Suppose there are 12 processing steps, with 12 units kept at each stage before moving in large batches to the next step (large-scale capital turnover), and it takes 1 minute to produce one unit (production rhythm). How does the cycle time change compared to a continuous flow without such intermediate stages? I will make a comparison in two scenarios: ① There is no continuous production of the handicraft; it takes 12 minutes to complete the first unit through all 12 processing steps, while the remaining units are produced at a rate of 1 minute each. ②When there are 10 work-in-progress items between processes, it takes 1 (production time) + 10 (waiting time for work-in-progress) + 1 + 10 + 1 + 10 + 1 + 10 + 1 + 10 + 1 + 10 + 1 + 10 + 1 + 10 + 1 = 100 minutes for the first product to go through all 10 processes. Thereafter, the remaining products are produced continuously at a rate of 1 minute per unit. In other words, when there is a product at the middle of the production process and batches of 10 items are produced for capital turnover, the production cycle changes from 10 minutes to 100 minutes, which is 10 times longer. The larger the scale of capital turnover, the longer the cycle time. (Consistent with the current situation of the vast majority of companies) There are roughly two such situations, and it does not take into account the impacts of various abnormalities on the progress of manufacturing. As can be seen from these two simple examples, the production cycle lengthens the delivery time for your orders; moreover, when there is a large volume of products and capital turnover, the production cycle continues to increase indefinitely, thereby affecting your ability to deliver goods. Solutions for lean production: 1) Remove obstacles through plans, freight logistics, process improvements, etc., to ensure smooth flow. 2) Improve the rational layout of equipment, streamline the process flow, and minimize capital turnover in the production process. 3) Improve production planning, apply line balancing techniques, create modular production lines, etc., to eliminate bottlenecks in the manufacturing process. 4) Improve the processing techniques and integrate the production processes to immediately reduce the manufacturing cycle time. 5) Improve tooling and fixtures to reduce capital turnover for large-scale production, thereby shortening the manufacturing cycle time. 6) Improve various process flows, particularly those with weaknesses, to reduce cycle times and increase productivity. 7) Improve response to malfunctions in machinery and equipment by implementing quick tool changes and standardizing operations, thereby reducing the time taken to address such issues. 8) Improve the production and manufacturing management model, enhance the organizational coordination capabilities in production and manufacturing, develop the ability to resolve issues swiftly, and reduce various risk factors. Through a series of posture improvements, cycle times have been reduced and the ability to deliver products improved, thereby effectively boosting productivity, enhancing on-site management capabilities, controlling costs, and minimizing various abnormalities. I want it; that’s precisely the strong and unique advantage of lean production.