A lean route to manufacturing survival

Abstract

Purpose – Aims to detail the ongoing implementation of lean manufacturing at a UK‐based electronic product‐manufacturing operation.Design/methodology/approach – Describes how and why a manufacturing operation, which had already seen major improvements that had made it a highly regarded plant, is adopting lean manufacturing as part of a manufacturing survival strategy. It also looks at some of the main Lean projects undertaken, the major benefits gained and the key lesson learned.Findings – While the operation's highly effective continuous improvement programme had delivered a major culture change along with significant OEE and quality improvements, the introduction of lean manufacturing highlighted that this had been achieved at the cost of creating a number of “islands of excellence”; resulting in high levels of WIP and long lead times. The implementation of lean manufacturing is now enabling this electronic products manufacturer to build on its excellent foundation of continuous improvement, and start t...