Applying lean principles for high product variety and low volumes: some issues and propositions

Abstract

Much has been written and talked about on the subject of lean manufacturing (LM) since the idea was first defined by Womack, Jones and Roos. This has stimulated academics and practitioners within various sectors of manufacturing industry to assess the viability of applying lean manufacturing principles to their circumstances. Addresses the vexing question asked specifically by many manufacturers in high variety, low volume (HVLV) segments: “Can we either directly or in adapted form apply LM principles and, if so, how do we go about it in our circumstances?” First describes the main characteristics of HVLV situations and then, drawing from experience of such organizations, contrasts these characteristics with those of the typical large lean manufacturing company. Uses this discussion as the framework to debate some of the major organizational and technological barriers which need to be overcome in applying lean principles in HVLVs. Then proposes approaches which feasibly can be considered when implementing lean manufacturing principles within a typical HVLV situation. Concludes with examples of the application of these principles to real situations in two case companies. The cases present instances of how organizations adapt lean principles to design and implement logistics and manufacturing operations for leanness, in creating and leveraging integrative supplier relationships and in evolving towards a process orientation which permits the institution of consistent measures to gauge strategic performance.