Lean Production At Portakabin-Case Study Essay.

Method Used

Discuss about the Lean Production at Portakabin-Case Study.

Lean Production at Portakabin

Lean production is an approach to reduce the loss and wastages in the process of production. It is considered as a better and efficient way of optimizing the output by using minimal input.  Lean production is considered as an efficient replacement for the traditional production methods.

The main problem noted were regarding t he employee dissatisfaction, failure of equipments and outdatedness of the production process. The employees were dissatisfied with the repetitive nature of the job. Any equipment failure at the work causes delay in the remaining process. There were issues when the machine became obsolete. These problems were occurring consistently causing   employee dissatisfaction. With the continuous problems, Portkabin is facing issues affecting the productivity. There is a need to apply an effective method in order to attain higher flexibility and efficiency at once. A new method need to be so that wastage can be reduced (Portkabin, 2017).

The lean production method was firstly adapted in Japan from 1950 to 1960 and was lately adopted by the firms in UK. This approach eliminates the wastage occurring in the material time and input of workers. There is a need to improvise the production through development of an effective quality method. A reduction in the cost will improve the overall production hence improving the competitiveness.  There are multiple of techniques that are been introduced o far to attain lean production. Among these techniques, cell production method arranges the employees in team. Every team is involved in a part of the whole process. This type of production increases team work and promotes employee satisfaction,

Under Kaizen the employees have to fulfil two assignments. Firstly they have to complete the given work and secondly they should suggest and implement the method. Continuous improvement is the part of the process contributing in a positive way.

Just in time approach implies that as the input is received they are utilizing it immediately in order to avoid wastage of time. This method uses computerized system of procurement in order to ensure that the order to delivered without any delay.  This method plays an important role while determining the status that there is no money held as stock. Portakabin is a construction company based in UK specialized i steel building for accommodation. After negotiation the company provides with the proper solution with everything.

Advantages and Disadvantages of Flow Production Method

Method used

Portkabin uses lean production method in the construction process. It includes Flow production, Cellular production and batch production. Through its effective manufacturing process the company is able to minimize cost. They have achieved quality assurance certification: ISO 9002. They are taking considerable lesser time for completion of the project. Portkabin has attained a high customer rating and standing out to be more efficient

Advantage of flow production method

Portkabin is been able to meet the target by manufacturing within the given time it is due to the capital intensive technique in the machines that are been used. The organization is highly mechanized and depends upon the technology for gaining productivity. Firm do incur lower cost to produce given products.  

Disadvantage of flow production method

The process is less flexible due to involvement of high end mechanization.  The products can’t be customizing according to the need of the customers.

Advantage of cell production system

This method can be adopted readily in the changing environment. The pending work inventories are kept low. This will increase overall output per worker and will reduce the time of production. The money saved can be used to procure more equipment. One can achieve immediate feedback on the changes affected.

Disadvantages of cell production system

The system relies on the initiative and input of the worker who is unreliable or absent due to any reason.

Advantage of batch production system

This method is used to produce differentiated products with a minimal cost by using the machine in a best possible way. The input can be purchased at a minimal cost by using the machines in a best possible way. The workers are deployed in the area of their expertise. They further have a positive implication on the quality of output in order to improv the skills.

Disadvantage of batch production system

Tis mechanism creates a backlog of work in progress it is a very difficult decision when one has to intricate decision and planning.  A lot of space is required that might lead to stock expiring or getting destroyed.

Method study

The use of method study allow in making comparison by identifying the best possible way of handling and scrutinizing the mean of production in a company.  This process is used in order to improve the quality work of the company. The method study can be used but the company in getting the best possible outcome. It involves selection of the operations which need to be done or studied in order to manage the company’s operation. The recorded information is read in detail by taking effective measures, the new system need to be managed properly in order to gain sustainable results. The system moreover ensures that the building is of the current standards that ensure effective measures for the purpose of relocation. The system ensures building in an effective way by ensuring availability of different components (Harris and McCaffer, 2013).

Advantages and Disadvantages of Cell Production System

Quality management system therefore ensures availability of goods in a best possible way and providing with an assurance to improve the chances of growth and development. It is through the quality management that the organization can gain effectiveness. The organization can thereby derive an effective procedure to deal with the situation. It is very well demonstrated by the company standards. The management system is effective and provides with the most appropriate character. The assurance guaranteed by them allow in gaining competitive advantage. Reduction in the cost will improve the overall production hence improving the competitiveness.  There are multiple of techniques that are been introduced o far to attain lean production (Morrissey and Browne, 2004)

JIT technique in meeting the target at Lilliput

The company has focused on improving the overall benefit by emphasizing on quality to be illustrated by the Portakabin Lilliput products. Lilliput Children’s Centres are designed to be child-focused.  The purpose is to meet tough safety and care standards. The purpose of the company is to create a protective environment. The Children’s Centres provide with a resource for the whole community that help in managing the resources in a well defined way. In order to gain proficiency with the time it is possible to gain a competitive advantage by developing effectiveness. There are possibilities where it is possible to build in half the time. The traditional methods decrease the overall productivity. For a better understanding it is possible to use Multi-functional rooms like kitchens, crèche facilities, and training rooms. This will help in organizing the work on a fast pace.  There are certain times when the functioning is delayed due to unforseen future (Kang and Bekkers, 2015). At time the function is delayed due to improper execution of projects. The process therefore allow in managing the resources in the best possible way. The Just in time approach will help them in utilizing the goods it right away in order to avoid wastage of time. This method uses computerized system of procurement in order to make certain that the order to deliver without any delay.  This method plays an important role while determining the status that there is no money held as stock. Portakabin is a construction company based in UK specialized steel building for accommodation.  After negotiation the company provides with the proper solution with everything. In order to meet the goal it is evident for Liliput to minimize the lag time (Hirano, 2016).

Advantages and Disadvantages of Batch Production System

Waste reduction methods at Portakabin

Portakabin lean production process encourages waste reduction. The organization is using Building in a modular way is a lean process. The off-site construction and installation of completed and fitted building can be managed by fewer workers that are required on site. This will require less transport.  Portakabin has been successfully been able to reduce the volume of waste sent to landfill by 60% over the last three years.  It is achieved due to the efforts by cutting down of the wastage. Portakabin has improved design to diminish waste in manufacturing. They have successfully achieved the objective by

• Through the smart design of the modules. This maximises the use of standard distance across materials.
• reprocess of resources, like door and window shapes
• By changing the materials used through insulating foam. This has allowed in reducing wastage of material by 10%
• Steel beams are supplied to the factory. Portakabin modules are pre-sized that do not require trimming is. This reduces the wastage created by wood particles or dust Recycling waste is one of the important aspects in Portakabin Group. They recycle 65% of waste generated in off-site manufacturing. The employees are trained to think about recycling. Recycling is an important component that requires to be carried at Portkabin in order to manage the building site. Portakabin has successfully designated a waste management teams. These are made up of a production manager and waste contractor. A permanent trainer works for the company and employees are regularly given refresher courses to update new ideas.  They are also using Pallets for transporting products that are recycled at every stage of the supply chain (Cannon and Hillebrandt, 2016.)

Management of wastage has majority of benefits for the people in order to gain competitive advantage .It allow in managing the effectiveness and reduce the overall wastage that occurs while managing the resources. They benefit Portkabin in

Financial benefits for Portakabin and its customers.-Financial benefits are one of the important components that are important to gain a competitive advantage. The Portakabin production methods reduce the cost of constructing keeping the cost low. The lead time can be reduced placing an organized function and creating better opportunity. This allow in managing the risk with an effective use of technology.  The latest technology works under controlled conditions and help in managing the affairs (Dennis, 2016).

Environmental benefits- There are numerous significant environmental benefits, including better thermal performance and Tests carried out on the Ultima buildings. This allow in managing the environment by 70% minimal air leakage. This allows in creating a proactive environment and is therefore enabling thermally proficiency.  With so many issues related to the environment it has become important to implement effective issues. There are certain necessary measures that are important to create a difference. The organization is uses ozone-friendly materials.  This has enabled managing the function in the best possible way (Monahan, Coates and Clarke-Hagan, 2014).  The organization is effectively manufacturing process that helps in managing the resources in an effective way. By following an efficient pattern the wastage can be reduced along with pollution. Smaller number vehicle actions to construction sites minimise traffic pollution and hence creating opportunities for recycling. The buildings are constructed in a well-defined way helping in allocating desired results within the section (Othman, 2015).

Social benefits to people and communities- The main financial benefits therefore include predictable construction. It is evident to note that the construction is not disrupted by weather conditions or site related problems. The company has a support system where 99.6% of Portakabin projects are delivered on time and on budget. The construction are carried out at a fast pace while meeting the basic requirements. The industry is involved in Building 50% faster than those in traditional building projects. At the same time they are able to control quality. The Systems is based on lean manufacturing techniques guaranteeing high quality at every stage of production.Social benefits is important in order to manage the society. It is therefore mandatory to provide certain level of benefits to the wider community. In this situation the organization is providing with ample of benefits in order to gain competitiveness.  They are looking for improved health and safety. In order to gain competitiveness it is important for an organization to improve the condition of the society in which they are living (Chalice, 2007). This will benefit everyone. Factory-based construction improves the quality of the company. Toyota has an effective waste management system. The company strive hard to reduce excess wastage caused during the operations. In this way they are able to gain a competitive advantage in the market. It is gainful for the business organization to find out an appropriate way to meet end results.  In a highly competitive economy and changing business behavior it is evident to look into an appropriate way through which one can gain sustainable result. In such a condition the purpose is to guarantee desired outcomes. This is only possible through determination of buying the input. By managing the goods it is possible to manage at minimal cost by using the machines in a best possible way. The workers are deployed in the area of their expertise. This method uses computerized system of procurement in order to ensure that the order to delivered without any delay (Fleischmann, et al 2014).  This method plays an important role while determining the status that there is no money held as stock. The organization can thereby derive an effective procedure to deal with the situation. It is very well demonstrated by the company standards. The management system is effective and provides with the most appropriate character (Lewis, 2000).

Method Study

Impacts on Portakabin of using lean production

The implication of technique in the company will be competent to recognize the best way of handling and scrutinizing the production in a company. It has to improve the quality work of the company normally in all the activities implemented not exclusive of the daily operations which are recurring. The method study by the company describes the best techniques that re appropriate in the execution of the company process. This occupies the selection of the process which needs to be complete or studied (Holweg, 2007).  There is a need to improvise the production through development of an effective quality method. A reduction in the cost will improve the overall production hence improving the competitiveness Innovation is considered as an important element to any market in order to figure out effectiveness timely. The traditional methods decrease the overall productivity it is therefore used as an important aspect to an organization. Use of knowledge is important to create something important. A new thing is obvious to gain a piece of equipment which are useful for a company to manage the potential to allow people to do things in different and better ways. Portakabin has successfully designated a waste management teams. These are made up of a production manager and waste contractor. It is through their vision the organization is able to reduce the excess wastage (Shah and Ward, 2007). Meanwhile it is understood that the Lean production will be used as efficient replacement for the traditional production method. The traditional methods are causing excess problem in attaining desired result. The productivity is actually hampered when an organization is unable to align its goal in a systematic way (Heizer, 2016.). Lean production has a long-term impact on the organization. It is thereby reducing the overall impact of the features that are important for gaining competency. The purpose of gaining competency is to attain effectiveness at work. One can find issues in carrying out the activity. On a long run the purpose of gaining sustainability is to maintain effective relationship. The lean production creates gap in attaining better understanding.

The main difficulty with managing the lean production is in term of dissatisfaction, failure of equipments and out datedness of the production procedure. The employees are highly dissatisfied with the repetitive nature of the job. Lean production causes problem that causes failure at the work and delay in the remaining process (Errasti, Rudberg and Corte, 2015). There were challenges where the machine became out of date. These problems accompanied with other caused delay in gaining effectiveness at work. The employees were consistently dissatisfied. All this has been affecting the productivity of the organization. Portkabin is facing issues affecting the productivity. There is a requirement to apply an effectual method to attain higher suppleness and competence at once. A new method need to be used so that wastage can be reduced (Cook, 2010).

Quality Management System

The lean production method was lately adopted by the firms in UK. This approach however eliminates the wastage occurring in the material time and input of workers. However it is suggested to manage the production through growth of an effectual superiority technique. A decline in the cost will get better production hence improving the competitiveness.  It is important for the organization in multiple forms hence guaranteeing lean production. This is highly impacting the organization in gaining goals. This technique put together the employees in team (Gangjee, 2013). Overall it helps in managing the activities in the best possible way. This type of production increase team work and promote employee satisfaction. Firstly they have to work and secondly they should propose and put into practice an effective method. Continuous development is the division of the process causative in an optimistic way. The main problem noted were regarding employee dissatisfaction and can be resolved through managing the process in an effective way. The different cause behind the failure has highly affected the organizational growth. It therefore had a long term impact having deliberate impact on attaining systematic growth. The employees were dissatisfied with the recurring nature of the job.  Any failure would directly affect the growth in the organization. It has become a matter of great importance to put together an effective tool and procedure for the remaining process. There were issues when the machine became obsolete.

Portakabin production methods decrease the cost of constructing high quality building projects. In this way the lead time amid a customer introducing an order and the conclusion product being prepared is much shorter. It is therefore able to match up with the use of the latest technologies under prohibited conditions.

In long run the company has to manage the effectiveness by developing better tool sand technology. This will guarantee better implementation of policies and deployment of goals in a significant way. This process therefore helps in measuring the sustainable impacts that are used for managing the activities as per the market requirements. This is only possible through determination of buying the input. By managing the goods it is possible to manage at minimal cost by using the machines in a best possible way. Portkabin is known for providing effective solution to help other organisations to supervise their altering accommodation requirements. They are using the modular buildings methods to put together lean production methods.

This method is providing them with a solution to overcome the problem that they are facing in order to carry forward the Lean processes providing an environmentally-friendly approach in a world of limited resources. Time is used more professionally. The purpose of this technique is to reduce wastage in order to cause efficient result at every stage of lean production.  The modular buildings can be used in a quick way. Problems can be reduced by associating with conventional new buildings such or by eliminating the gaps. The net consequence is only possible if the company is able to match up with the customer’s expectations. The organization can thereby derive an effective procedure to deal with the situation. It is very well demonstrated by the company standards.

Conclusion

To conclude, it is eventually important to manage the resources in the best possible way. It is therefore essential to reduce the wastage and to attain efficient result by promoting growth and development. Portkabin is using lean production method in the construction process. It includes Flow production, Cellular production and batch production. Through its effective manufacturing process the company is able to minimize cost. The purpose is to understand the technique in order to manage the effectiveness. There is a necessity of reducing the excess wastage in the process by implementing long-term better activities. The organization can only gain better results if it implements an efficient methodology

References

Cannon, J. and Hillebrandt, P.M. eds., 2016. The Management of Construction Firms: Aspects of Theory. Springer.

Chalice, R., 2007. Improving healthcare using Toyota lean production methods: 46 steps for improvement. ASQ Quality Press.

Cook, S., 2010. Customer care excellence: How to create an effective customer focus. Kogan Page Publishers.

Dennis, P., 2016. Lean Production simplified: A plain-language guide to the world's most powerful production system. Crc press.

Errasti, A., Rudberg, M. and Corti, D., 2015. Managing international operations: configuration of production network for SMEs.

Fleischmann, A., Schmidt, W., Stary, C., Obermeier, S. and Brger, E., 2014. Subject-oriented business process management. Springer Publishing Company, Incorporated.

Gangjee, D.S., 2013. Property in Brands.

Harris, F. and McCaffer, R., 2013. Modern construction management. John Wiley & Sons.

Heizer, J., 2016. Operations Management, 11/e. Pearson Education India.

Hirano, H., 2016. JIT Implementation Manual--The Complete Guide to Just-In-Time Manufacturing: Volume 2--Waste and the 5S's. CRC Press.

Holweg, M., 2007. The genealogy of lean production. Journal of operations management, 25(2), pp.420-437.

Kang, B. and Bekkers, R., 2015. Just-in-time patents and the development of standards. Research Policy, 44(10), pp.1948-1961.

Lewis, M.A., 2000. Lean production and sustainable competitive advantage. International Journal of Operations & Production Management, 20(8), pp.959-978.

Monahan, J., Coates, R. and Clarke-Hagan, D., 2014. Overcoming the Barriers of Green Innovation in Construction Projects Through Its Successful Management. RCOM A, p.123.

Morrissey, A.J. and Browne, J., 2004. Waste management models and their application to sustainable waste management. Waste management, 24(3), pp.297-308.

Othman, A.A.E., 2015. An international index for customer satisfaction in the construction industry. International Journal of Construction Management, 15(1), pp.33-58.

Portkabin, 2017. Online. Available at: https://www.portakabin.co.uk/ Accessed on: 15 August 2017

Shah, R. and Ward, P.T., 2007. Defining and developing measures of lean production. Journal of operations management, 25(4), pp.785-805