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Hi All,
Can any one explain regarding the difference between lean & descrete manufacturing, or it is same ?
Regards
Rehan Ahmed
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They are not alternatives.
Lean is more of a management concept.
A manufacturing plant might be lean without being discrete but in practice lean tends to be used more with discrete. Production will typically be of a 'discrete quantity' and may involve discrete stages (sub assemblies).
Some industries like: oil and gas, iron smelting, chocolate bars, pizza manufacture are more likely to be a continuous process of constant production with no interim stocked sub assembly product.
Lean is more of a philosophy to reduce waste and to increase agility to respond - i.e. it tries to eliminate steps that do not add value. Holding stock and wip adds cost - and the more that is held the less agility there is to make a variety of products in a short time or to bring a new product to market quickly (ie. all the old stock needs to go first). Lean typically works on a demand pull from the next operational step rather than a planned push to make and sell.
A lean approach might focus on how to reduce changeover times to make small batches economic. It may look at flatter boms and flowline processes.
Traditional make to stock and sell might look more at economy of scale to get better overhead recovery.
Lean works pretty much the same way in AX as Discrete... It uses another management principle.
The idea is that if you have very regular costs or do not want to track production variations it is pretty handy.
At the core LEAN manufacturing backflush BOM and route at a given quantity (kanban size) when the production barcode is scanned. You move the raw materials from stock to cell by a transfer kanban. The chain of actions (transfer, production, transfer, production...) and so on is known as a value stream. So each step is just a barcode scan and that moves or assemble an set of items. Quantity is dependent on the kanban size.
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