Implications of Lean Manufacturing | Advanced Manufacturing System | SNS Institutions

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Manufacturing systems have evolved over time to meet changing market demands. Two major approaches are Traditional Manufacturing and Lean Manufacturing. While traditional manufacturing focuses on mass production and efficiency through scale, lean manufacturing emphasizes waste elimination and continuous improvement.

Traditional Manufacturing
Traditional manufacturing, also known as mass production, is based on producing large quantities of standardized products. The main objective is to maximize output and minimize unit cost by using high-capacity machines, large batch sizes, and specialized labor.

In this system, production is usually push-based, meaning products are manufactured according to forecasts rather than actual customer demand. This often leads to excess inventory, longer lead times, and higher storage costs. Departments such as design, production, quality, and maintenance work in silos, which may cause communication gaps and slow decision-making.

Quality control in traditional systems is mainly done through inspection after production, so defects are detected late. Rework and scrap are common, increasing overall cost. Workers usually perform repetitive tasks and have limited involvement in problem-solving or decision-making.

Lean Manufacturing
Lean manufacturing is a modern approach developed from the Toyota Production System (TPS). Its primary goal is to maximize customer value while minimizing waste. Lean focuses on producing only what is needed, when it is needed, and in the required quantity.

Lean uses a pull system, where production is driven by actual customer demand. This reduces overproduction and inventory. Lean identifies seven major wastes (muda): overproduction, waiting, transportation, excess inventory, motion, overprocessing, and defects.

Unlike traditional systems, lean emphasizes continuous improvement (Kaizen) and employee involvement. Workers are encouraged to suggest improvements and solve problems. Quality is built into the process using methods like Poka-Yoke (error-proofing) and Jidoka (automation with human intelligence).

Lean manufacturing also promotes tools such as 5S, Kanban, Just-In-Time (JIT), Value Stream Mapping (VSM), and Standard Work to improve flow and reduce waste.

Key Differences
Aspect Traditional Manufacturing Lean Manufacturing
Production system Push-based Pull-based
Batch size Large Small
Inventory High Minimal
Lead time Long Short
Quality control End inspection Built-in quality
Worker role Task-oriented Multi-skilled, problem-solving
Focus Output and efficiency Value and waste elimination

In summary, traditional manufacturing is suitable for stable markets with predictable demand and standardized products. However, in today’s competitive and dynamic environment, lean manufacturing offers greater flexibility, better quality, lower costs, and higher customer satisfaction. By focusing on waste reduction and continuous improvement, lean manufacturing creates a more responsive and sustainable production system.