Lean Machine


Dated: 1 June 2008
Daphne Tan, Editor, Asia Food Journal

What do music and manufacturing have in common? Henry Ford, who first established mass car production, conceived the idea of a single product assembly line from the cut-up operations of a Chicago slaughterhouse. Japanese car-maker Toyota later reworked the system to include a range of products, achieving signifi cant productivity gains and establishing what has become the basis of manufacturing practice.

This was to mark the beginnings of "lean" a term coined to typify minimal waste, productive maintenance and consistent output in manufacturing. Cardiff Business School's food process unit, in a 2006 paper, refi ned the lean concept by identifying fi ve core characteristics: customer focus, value-add to products, strategic partnerships with customers and suppliers, continuous process and product improvement, and embracing best practices.

Returning to the setting that fi rst inspired the original assembly line, studies of fi ve conveyor belt slaughterhouse operations found that manual cutting and deboning work were best performed when line speeds followed rhythmic beats marked by precise time intervals, not unlike the metronome used to keep time in music. In such cases, worker effi ciency and quality of work improved, and ineffi ciencies were reduced. Moving to repetitive rhythms, experts believe, helps processing lines achieve those tenets of lean.

This could perhaps explain why human beings are instinctively drawn to beat-perfect mechanical movements. At the Interpack show, it was not hard to catch moments where others, like myself, were similarly mesmerized by the capacious set-ups of precision-timed, lyrically paced robotic activity.

Details of the show review are inside.

 
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