The global marketplace has witnessed an increased pressure from customers and competitors

The global marketplace has witnessed an increased pressure from customers and competitors in manufacturing as well as service sector (Basu, 2001; George, 2002). Due to the rapidly changing global marketplace only those companies will be able to survive that will deliver products of good quality at cheaper rate and to achieve their goal companies try to improve performance by focusing on cost cutting, increasing productivity levels, quality and guaranteeing deliveries in order to satisfy customers (Raouf, 1994).

Increased global competition leads the industry to increasing efficiency by means of economies of scale and internal specialization so as to meet market conditions in terms of flexibility, delivery performance and quality (Yamashina, 1995). The changes in the present competitive business environment are characterized by profound competition on the supply side and keen indecisive in customer requirements on the demand side. These changes have left their distinctive marks on the different aspect of the manufacturing organizations (Gomes et al., 2006). With this increasing global economy, cost effective manufacturing has become a requirement to remain competitive.

To meet all the challenges organizations try to introduce different manufacturing and supply techniques. Management of organizations devotes its efforts to reduce the manufacturing costs and to improve the quality of product. To achieve this goal, different manufacturing and supply techniques have been employed. The last quarter of the 20th century witnessed the adoption of world-class, lean and integrated manufacturing strategies that have drastically changed the way manufacturing firms leads to improvement of manufacturing performance (Fullerton and McWatters, 2002).

Read textbook chapter 7 or secondary data on the internet and answer the following questions.

Question:

1.Why big Manufacturing Companies adopted Lean Thinking and the JIT model? (3 Marks)

2.Discuss major types of Waste, and why overproduction is the biggest waste companies must keep in mind during production. (3 Marks)

3.With the initiation of artificial intelligence. The agile supply chain is a perfect concept for future SCM? Give reasons with examples. (3 Marks)

4.APA style Reference ((1.0 Marks)

Each answer should be within the limit of 300- 400 words.

The Answer must follow the outline points below:

Lean Thinking and JIT Concept

Agile Supply chain

Their Main functions

Reasons with suitable Examples

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Sample Answer

 

 

Why Big Manufacturing Companies Adopted Lean Thinking and the JIT Model (3 Marks)

The intense global competition in the late 20th century forced manufacturers to adapt and improve. Lean thinking and the Just-in-Time (JIT) model emerged as key strategies to achieve this. Here’s why big manufacturers adopted them:

  1. Cost Reduction: Lean principles eliminate waste in all processes, minimizing unnecessary spending on materials, labor, and storage. JIT focuses on receiving materials exactly when needed for production, reducing inventory carrying costs.

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  1. Improved Efficiency: Both approaches promote streamlined production flows, minimizing delays and bottlenecks. This allows for faster production cycles and quicker response to market changes.
  2. Enhanced Quality: Lean emphasizes continuous improvement, leading to defect reduction and higher quality products. JIT minimizes handling and storage, reducing the risk of damage to materials.

These combined benefits translate to a significant competitive advantage: delivering high-quality products at lower costs and faster turnaround times.

Major Types of Waste and Why Overproduction is the Root Cause (3 Marks)

Lean thinking identifies seven major types of waste in manufacturing:

  1. Overproduction:Producing more than what is immediately needed by customers.
  2. Waiting:Time spent waiting for materials, instructions, or equipment.
  3. Transportation:Unnecessary movement of materials or products.
  4. Inventory:Excess stock of raw materials, work in progress, or finished goods.
  5. Overprocessing:Performing unnecessary work on products beyond customer requirements.
  6. Defects:Rejects and rework due to errors in production.
  7. Unused Talent:Not fully utilizing the skills and knowledge of employees.

Overproduction is considered the root cause of all other wastes. By producing more than needed, companies create excessive inventory, which leads to waiting (for materials to be used), transportation (moving the inventory), and potential defects (due to longer storage times). Addressing overproduction through JIT principles helps eliminate these downstream wastes.

Agile Supply Chain and its Advantages with AI (3 Marks)

An agile supply chain is a flexible and responsive system that adapts to changing customer demands and market conditions. It emphasizes collaboration among all partners in the supply chain, from suppliers to distributors. With the rise of artificial intelligence (AI), agile supply chains become even more powerful:

  • Demand forecasting:AI can analyze vast amounts of data to predict customer needs more accurately, enabling manufacturers to adjust production plans accordingly and avoid overproduction.
  • Inventory optimization:AI can optimize inventory levels throughout the supply chain, minimizing storage costs while ensuring sufficient stock to meet demand fluctuations.
  • Risk mitigation:AI can analyze historical data and identify potential disruptions (e.g., supplier shortages) in real-time, allowing the supply chain to react proactively and find alternative solutions.

Example: A clothing retailer can use AI to analyze customer trends and social media data to predict styles and colors that will be in high demand. They can then adjust their production plans and communicate these changes to their suppliers, ensuring they have the right materials on hand when needed.

By leveraging AI, agile supply chains can become even more responsive, efficient, and resilient, leading to a significant competitive advantage.

 

 

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