In this globalisation where company has issue to produce profitability and catering to changing need of customer become challenges. Lean manufacturing gives you the flexibility to manufacture the products according to the needs and demand of the customer. Customer is not willing to pay more prices on the contrary

Lean manufacturing or lean production, is a systematic method of elimination of waste within a manufacturing system. Lean also takes into account which created through overburden and was created true unevenness workload. Lean management is a concept related to manufacturing sector it is applicable to Other industries as well Such as retail, Service Sector.

Advantages of Lean Manufacturing, improve quality increase efficiency by eliminating waste and reducing cost. These all positive impacts improve the performance of the organisation some of the benefits observed during implications of as below

Reduced cost reduced – Cost by reducing cycle time, increase productivity ,reducing machine downtime, increase output from existing facility and eliminating the bottlenecks
Reduce lead time – Lean manufacturing help to reduced lead time, reduced with effect of reduce cycle time and also reduce work in progress inventory.
Waste reduction -all form of waste like , defect, Over productions , waiting for information, non value added activities, Transportation, inventory, motion and unutilised talent, are the waste that can be reduced by reducing Lean Manufacturing.
Improved productivity – improve productivity by improving labour productivity by reducing ideal time and ensuring that labor are not doing unnecessary task or motions
Reducing work in progress – reduction in WI, production state is known as inventory (WIP) at all state of production
Reduce defects – By quality improvement elimination of various errors and unnecessary physical waste including excess use of raw material inputs prevent defects and costs associated with repairing
Reducing waiting Time – time between process stage as well as process preparation time.
Improve flexibility by reducing lean management pdf change over time – Minimum changeover cost Time (SMED) improve the flexibility to produce more range of products
Better utilization of space and equipment – by eliminating bottlenecks and maximizing the rate of production with existing equipment with minimizing machine down time
Benefits of Lean Manufacturing
Benefits of lean Manufacturing are listed below. we have created a remarkable improvement in the company. For More information please visit our you tube channel.

Over Production – Producing Items for which there are no orders, which generates such wastes as overstaffing and storage and transportation costs because of excess inventory.
Waiting – Workers merely serving to watch an automated machine or having to stand around waiting for the next process step,tool,supply,parts,etc., or just having no work because of stock outs,lot processing delays,equipment downtime, and capacity bottlenecks.
Unnecessary transport or conveyance – Carrying work in process long distances,creating inefficient transport,or moving materials,parts,or finished goods into or out of storage or between processes.
Over processing or incorrect processing – Taking unneeded steps to process the parts. Inefficiently processing due to poor tool and product design,causing unnecessary motion and producing defects. Waste is generated when providing higher-quality products than necessary.
Excess inventory – Excess raw material, WIP, or finished goods causing longer lead time,obsolescence,damaged goods,transportation and storage costs and delay. Also, extra inventory hides problems such as production imbalances,late deliveries from suppliers,defects,equipment downtime and long setup time.
Unnecessary moment – Any wasted motion employees have to perform during the course of their work, such as looking for, researching for, or stacking parts,tools etc. Also,walking is waste.
Defects – Production of defective parts or corrections. Repair or rework,scrap,replacement production,and inspection mean wasteful handling time,and efforts.
Unused employee creativity – Losing time,ideas,skills,improvements,and learning opportunities by not engaging or listening to your employees.

7 habits of Highly Effective people and tqm

ighly effective people have particular good habits that make them so and therefore productive. Effective people are always active and stable with their mindsets.


Stephen Kovai has put forward the 7 habits of highly effective people as follows


Proactive leaders and employees accept responsibility for their own behavior without blaming and accusing others. effective people act accordingly to values and principles say identify and commit to live by; and focus on the cycle of influence, where in they can make a difference, as opposed to spending time in their circle of concern, where they have little ability to contribute.

Where effective people are involved in change, proactive leaders share their own responsibilities and while working within the circle of influence make efforts to fulfill them. They don’t pass the buck and point fingers. They are doers, not complainers. Rather than resist changes, they involve themselves in its assessment, creation and effective implementation to the maximum degree possible.



Where should people find the security within organisations? Not in changeable and Temporary structures and Systems.

Security lies in the clearly identifiable mission, Vision and principles that are constantly reflected in the behaviour of leaders and managers. Employees place trust in the constancy of that mission and in the unchanging principles of the organisation. When people feel secure in the mission and principles of the organisation, they feel less threatened and thus offer less resistance to change in structure and Systems. the leader as facilitator. Leaders are responsible to facilitate the development of deeply shared mission and vision within the organisation, including each sub unit. The habit of beginning with the end in in mind applies personally as well as organisational. When people within the organisation recognize a common overlap between their personal values and mission and those of the organisation they serve, the ground is prepared for growth and development of the people who control all the other resources of the organisation.


It is important for people not to less than the mission, vision, principles and values of the organisation, but, also to understand and share through involvement and commitment in its strategic action Plans. The difference is that understanding that strategy will change with the changing environment and internal resources, while core mission and principles will be more confident and stable

Effective strategy is commitment to putting First Things First as explained in the ensuing points, First Things First items definitely include the following:

Planning and prioritizing the allocation of resource
Understanding and prioritizing stakeholder needs
Focusing time and energy on important though Not yet, urgent requirements of creating opportunities.
Developing relationships.
Innovative thinking
When people are clear about their roles and action plans to achieve them, they appreciate that change is essential to long term success. They are better to accept change as something normal, rather than resist the movement from the current comfort zone.


Trust is built when people see by constant practice that leaders seek mutual benefit for employees and other key stakeholders Stage in all their quality change decisions and initiatives. True Win-Win thinking required seeking to understand needs and wants of stakeholders and synergistic creation of there alternatives that cooperatively balance completing needs and scarce resources.

When the paradigm of internal cooperation and common benefit permits culture, change initiatives and quality improvement requirements receive early support, not suspicion. Through this paradigm a framework is created for open dialogue on the genuine merits of change and the most effective options for implementation, rather than on refusing private agendas and overcoming the fear and distrust around what are they going to do to me now attitude.


Central to effective change based on win win thinking is constant opinion of two way communication between all participants in the organisation through a stakeholders information system [SIS] this two way communication process includes-

Management with employees.
Upper management with middle management.
Departments and divisions with each other
Headquarters with the field.
The main organisation with external stakeholders and external stakeholders with each other.
understanding comes from being understood. The key to being understood is first to understand. When did us demonstrate consistent commitment to:

Understanding the stakeholders needs desires and ideas before making decisions and
Effectively facilitating stakeholders understanding and commitment to those decisions a paradigm of genuine dialogue and Synergy is developed. With such understanding change is more readily accepted and implemented.
The more timely, accurate and relevant the information feedback leaders receive from all key stakeholders, the better prepared their to initiate and implement change in structures and in cultural norms that represent the realities of the environment and the constraints of organisational resources.

Such 360 degree feedback process and then widespread distribution Analysis and discussion concerning the feedback results, can provide management and decision makers with valuable capability to foresee trends, to better meet stakeholders needs, to make organisational strategic adjustments and then to modify systems and structures as necessary both to address problems and to create and take advantage of critical opportunities.

Synergy 2 + 2 = 5 effect is a fruit of Win Win thinking and empathetic communication. Through constant synergistic dialogue, the creative capabilities of the organisation are unleashed through the involvement of all appropriate parties to: To read more blogs visit www.greendot.co.in

Assess and evaluate organisational strength, weaknesses, opportunities and threats pertaining to meeting stakeholder’s needs.
Develop and implement solutions addressing any and all of them.
Calling and data developed through SIS , the organisation empowers itself through Synergy to energize its collective intelligence, experience and wisdom to make the right moves in the right way and at the right time. When people are shown respect and hour through meaning full involvement in analysis, decision making and implementation, the change resistance is transformed to support for change.


Continuous improvement means continuous change. When people within organisations commit to the principal that the status quo means continued Innovation and progress, They reduce resistance to change and look forward to making the next series of structural and process improvements even more significantly effective.

As with any Complex ecosystem, organisational effectiveness and quality comes throgh balance. change for the sake of change alone and change so frequent that it becomes disruptive, uneconomical and in efficient as well as ineffective does not constitute quality. Leaders must never be afraid to Institute change. but they must also never click here be afraid to conclude that staying in the present course is, indeed the best course.



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