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Lean Production for the Wood Products Industry

A research project in progress on the Web!

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The Pennsylvania wood products industry suffers from increasing competition that is causing a reduction in jobs and economic value-added to the Commonwealth. One manufacturing strategy that holds great promise for increasing the competitiveness of secondary wood producers is lean production, developed from the Toyota Production System
http://www.dig.bris.ac.uk/teaching/m_o_i/studen10.htm . Many of Pennsylvania’s leading wood products manufacturing companies are already involved with lean manufacturing, or are trying to determine how lean best fits their enterprise; however, we believe that strictly applying lean techniques to a wood manufacturing environment may in fact do more harm than good. We therefore propose to conduct applied research that will clarify and quantify how secondary wood manufacturers should use lean. We will then compare these results to existing lean manufacturing curricula to determine how they should be modified. Finally, we will deliver an executive-level educational program to inform industry leaders about lean as a strategy.

 !    Lean Research Project by Stages
Phase 1 Funded Research Proposal (PA HDC)
The Research Planning Presentation
The Data Collection Worksheet

Mid-Project Slide Presentation

Phase 2 Funded Research Proposal (USFS)
Phase 2 Company Invitation
Published Report: The Lean Index
Phase 3 Funded Research Proposal (USFS)
 !   Key Hypotheses as they are formed and concluded through this research
1.  To re-define Lean requirements for wood processing companies, specific components of lean production must be identified and quantified. Then, quantitative models may be developed and quantitified and encoded in an industry-specific Lean Index (LI). -Done-
2.  LI can be modeled as a function of macro-level factors and micro-level factors. For validation of individual models, correlations must be established to test the equivalency of LI(macro) to LI (micro). -Done-
3.  Lean may be modeled based on the lag times of material moves through the process.
4.  Primary wood processing is leaner than secondary wood processing. -True-
5.
Lumber drying is the least lean operation in the hardwood industry. -True-
6.
"Leaner" does not necessarily mean lower cost.
7.
"Leaner" does not necessarily mean lower inventory. -True-
8.
"Leaner" operations exhibit higher throughput.
9.  A supply chain of integrated sub-contractors is leaner overall than a single vertically integrated company.
10. Energy usage is a critical component of "leanness" in wood products operations. -True-
11. Pull production results in leaner operation than push production for a given facility.