Some challenges faced during the process of optimization can include resistance to change from employees, the need for significant upfront investment in new equipment or training, potential disruptions to production during the transition period, and the difficulty of accurately identifying inefficiencies and the most effective solutions. It's also important to maintain a balance between optimization and flexibility, as overly rigid systems can struggle to adapt to new circumstances or unexpected problems.
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During the 1970s, Japanese firms like Toyota optimized their factories to remove as much unnecessary work as possible. This ensured that they could accurately assemble their products in as little time as possible. For example, they would arrange workspaces in the most optimal configuration to reduce the time that workers spent twisting and turning. As a result, Japanese products were assembled faster and more reliably than their American counterparts.