Manufacturing and service industries in India have taken to lean concepts and techniques
as these provide many advantages. Some of the advantages are: increased productivity,
better control on quality, lower cost, and improved employee involvement; all of
these, concurrently resulting in greater customer satisfaction. Customers, on the other hand,
have become choosy. Unless a company caters to the exact choice of the customer, another crane
may catch the fish. Choice of the customer needs to be met by producing a product at his
desired quality level, affordable cost and timely delivery, which will give him satisfaction and may
lead to repeat purchase. However, for this to result in a sustained competitive advantage, the need
for target costing and the corresponding modifications required on the costing policies and
practices needs to be examined.
Taichi Ohno first developed the lean concepts at Toyota (Womack, 1998). The principles
he developed are applicable, both to the manufacturing and the service sectors
(Lakshminarasimha, et al., 2005). To enable a proper perspective on the concepts of lean, an attempt is made to
briefly recapitulate them.
Value Stream: The value stream is the list of all the activities/processes required to bring
a product or service passing through the critical tasks of problem solving, information
gathering, and physical transformation or service compliance, e.g., is the customer for a can of cola
really concerned where the metal for the can is mined or the wasteful (MUDA?) transportation
it undergoes from the mine to bottler (or rather canner?). Mined in Australia, it is then converted
to powdery alumina and transported to Norway or Sweden for smelting into aluminum.
From there to Germany to a hot rolling mill and then onwards to England for making the cans.
The amount of transportation which goes into the manufacture of Cola cans is literally MUDA. This
is depicted in the Figure 1. As depicted, the value stream would include all value-creating
activities right from the decisions at the concept stage of the product or service to a cost target, to
the processes used to deliver it to the end customer, continued service till the maturity of the
product (or till the product is retired, renewed, assigned or extinguished).
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