Lean Production System (LPS)

MARii’s Lean Production System (LPS) programme was first introduced in 2012 in collaboration with Malaysian car manufacturers PROTON and PERODUA, in an effort to increase the capabilities and competitiveness of local automotive component manufacturers. Today however, the programme is no longer exclusive to the automotive industry but is also being offered to all companies in the manufacturing sector.

The programme provides both technical assistance and consultative assistance to companies with the objective of enhancing productivity within manufacturing, and cultivating lean practices that would enable them to become world class component manufacturers. The ultimate goal is to for companies to continually enhance productivity and efficiency while minimizing or eliminating wastage within the manufacturing operations.

Companies that undergo the programme are benchmarked against the best production practices and standards embraced by Multi National Companies (MNCs) and evaluated in three key LPS factors that include management; just in time (JIT); and jidoka (Japanese system) or built in quality. Industry experts are then engaged as coaches to conduct training for each company and target improvements are identified and carried out.

MARii offers four specific modules within the LPS programme which manufacturing companies can select from depending on their areas of priority or preference. These modules include: 

  • LPS KARAKURI 

Karakuri is a Japanese word to describe the use of mechanical devices that does not use electricity, pneumatic or hydraulic power sources to assist with tasks. These devices are also not controlled by a computer but rather by design of the mechanics, using gravity, springs, kinematics, counterweights, human muscle, weights, pendulum, seesaws and gears to manipulate objects. Participating companies will be taught basic mechanism concepts, design and assembly; they will learn how to sketch, measure, dismantle, and assemble the various mechanisms; they will be taught how to fabricate a karakuri model at a selected production line; and they will learn how to fabricate a long lasting, less maintenance and low cost karakuri device.

  • LPS EFFECTIVE PRODUCTION PLANNING 

This program is focused on enhancing the understanding of choosing the correct system in order to meet customer requirements. It is the administrative process that takes place in manufacturing activities to ensure customer demand can be met and fulfilled, both in terms of quality and timely delivery.

  • LPS QUICK CHANGE OVER 

Quick Change Over essentially reflects the amount of time taken to change a piece of equipment from producing the last good part of the previous production run to the first good part of the following run produced at nominal speed. The program is designed to reduce the amount of time taken to complete equipment changeovers.

  • LPS JUST-IN-TIME AND BUILT IN QUALITY 

Manufacturing is not just about the final product being made just in time, but also concerns raw materials being delivered to the assembly line when needed. This method seeks to ensure that the raw materials and components required arrive at the respective work stations during the production process as close to when they are needed for assembly which translates into reducing a company’s cost of holding raw parts as extra inventory.

Upon being selected for the LPS programme, companies will first undergo a Supplier Competitiveness Assessment Programme, before its top management given a detailed insight into lean production systems and to gauge their expectations. This will be followed by classroom training as well as coaching and mentoring, with the entire programme taking between four and five months to complete.

Besides being introduced to comprehensive LPS modules, theory and practical simulations, companies will also transform one of their production lines into being fully LPS-compliant during the course of the coaching and mentoring process.

The important areas addressed in implementing LPS among others include problem identification and solving;  material information and flowchart design; visualization activities; process flow study; safety awareness; cycle time study; lead time calculation; work in progress reduction; line and manpower balancing; overall equipment effectiveness; and push & pull product verification.