How do you incorporate lean principles and practices into your production scheduling process?

1 Understand customer value

Lean production is based on the concept of value, which is defined by what the customer is willing to pay for. Therefore, the first step in creating a lean production schedule is to understand your customer value proposition and align your processes and products accordingly. You can use tools such as value stream mapping, voice of the customer, and quality function deployment to identify and eliminate any activities or features that do not add value to the customer.

2 Implement pull system

A pull system is a lean technique that involves producing only what is needed, when it is needed, and in the amount that is needed, based on the actual demand from the customer or the downstream process. A pull system reduces waste, inventory, and lead time by avoiding overproduction and excess stock. You can implement a pull system in your production scheduling by using tools such as kanban cards, reorder points, and supermarket systems to trigger production based on consumption.

3 Adopt flexibility and agility

Flexibility and agility are key characteristics of a lean production system that enable you to respond quickly and effectively to changes in customer demand, market conditions, or production issues. Flexibility and agility require you to have a cross-trained and empowered workforce, a modular and adaptable product design, and a dynamic and responsive production schedule. You can adopt flexibility and agility in your production scheduling by using tools such as heijunka, mixed-model scheduling, and level loading to balance the workload and smooth the flow of production.

5 Integrate technology and automation

Technology and automation are powerful enablers of lean production that can help you improve your productivity, quality, and reliability. Technology and automation can help you automate repetitive or low-value tasks, enhance your data collection and analysis, and optimize your decision-making and coordination. You can integrate technology and automation in your production scheduling by using tools such as ERP, MRP, APS, and IoT to streamline your information flow, synchronize your activities, and monitor your performance.

6 Collaborate with stakeholders

Collaboration is a vital element of lean production that involves working together with your suppliers, customers, and employees to create value and achieve mutual goals. Collaboration can help you reduce waste, improve quality, and increase satisfaction by aligning your expectations, sharing your information, and solving your problems. You can collaborate with stakeholders in your production scheduling by using tools such as supplier partnerships, customer feedback, and team meetings to coordinate your plans, exchange your inputs, and align your outcomes.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?