Barriers to JIT/Lean production: A study of logistical constraints at Celsa Steel, UK
Cardiff Metropolitan University
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This dissertation focuses on the barriers that have been studied by many literatures that discuss concepts of lean manufacturing and Just-in-time (JIT) production. Logistics plays a very important role in making JIT and lean production successful and the barriers that cause problems have been identified and analyzed in the case study company. Along with physical factors there are human factors as well that emerge as a potential barrier to businesses. A questionnaire, observation and document and secondary data analysis helped the researcher to understand the effects of the physical factors as a barrier. Interviews with managers and consultants helped identify the operational and human aspects that emerge as a barrier. With the data obtained from the study, it could therefore be concluded that 'lean logistics' has a very important role in making lean manufacturing a success. Effective human resource management is necessary as well to ensure that the systems in place for effective lean working are implemented effectively and for people to be educated, trained, applauded and motivated to ensure the ongoing success of the venture. It is also concluded from the research that some concepts of 'lean working and thinking' that have worked well in different companies and countries don't necessarily work in others. Therefore a cultural analysis of an organization before implementing lean or JIT production will help identify the constraints before making an effort to move them. These are further areas of research that could be implemented to obtain potential benefits in terms of avoiding 'muda' and saving money in terms of energy costs and by the way of working lean.
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