Lean Manufacturing | What is Lean Manufacturing?

Lean Manufacturing | What is Lean Manufacturing?

→ Lean Manufacturing is a Japanese concept.
→ Lean Manufacturing is a systematic approach to identifying and eliminating waste (non-value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection.
→ Lean manufacturing is a methodology that focuses on minimizing waste within manufacturing systems and simultaneously Lean manufacturing maximize productivity.

1) History of Lean Manufacturing:

→ The Milestone wise history of Lean Manufacturing is mentioned below:
History of Lean Manufacturing

2) What is Lean Manufacturing?

→ Lean Manufacturing is all about the optimizing processes and eliminating waste.
→ By Lean manufacturing, we will become more efficient in our manufacturing.
→ In Lean manufacturing, we have to find waste in our process and cut it out and the process will become lean.
→ Lean manufacturing is a systematic approach to identifying and eliminating waste through continuous improvement in our process.
Lean Manufacturing | What is Lean Manufacturing?

Lean Manufacturing | What is Lean Manufacturing?

→ Lean manufacturing is the production of goods using less of everything compared to traditional mass production:
   → less waste,
   → the less human effort, 
   → less manufacturing space, 
   → the less investment in tools, 
   → less inventory, 
   → less engineering time to develop a new product.

3) Goals of Lean Manufacturing:

    1. Cost Reduction by Elimination of Waste 
    2. Creating Conditions for Improving Product Quality 
    3. Quality First Time Through
    4. Customer Satisfaction 
    5. Building In Quality at Each Process
    6. Awareness of Wastes related to all process 
    7. The Added Value of Repairs
    8. Motivate all workers towards continuous improvement
    9. Streamline or smooth process flow etc....

4) 8 Wastes in Lean Manufacturing:

→ The 8 Wastes in Lean manufacturing is: Acronyms - TIMWOODS

     (1) Transportation Waste in Lean manufacturing: Do you move materials efficiently? Are you working with optimum transportation?

     (2) Inventory Waste in Lean manufacturing: Are you have work in progress inventories too high? Do you buy too the much raw material that needs to be stored for a while before it’s used?

     (3) Motion waste in Lean manufacturingDo people and equipment move between tasks efficiently?

     (4) Waiting waste in Lean manufacturingHow much time is consuming between your production steps? Does someone have to wait for someone else to finish a task?
     (5Over Production waste in Lean manufacturing: Are you producing the right amount of product to meet your consumers' demand?

     (6) Over Processing waste in Lean manufacturingDo you work on the product too many times?

     (7) Defects waste in Lean manufacturingHow much time do you spend finding and fixing production mistakes?

     (8) Skills sets (Non-utilized talent) waste in Lean manufacturingDo you use workers efficiently?

8 Wastes in Lean Manufacturing

5) The Key Points in Lean Manufacturing:

→ Teamwork: Form a team of people, that actually do the work
→ Observe: Analyse the current situation
→ Ideas: The team develop ideas on how to eliminate the waste
→ Communication: Make sure everyone knows the goals, the changes being made, the success and the failures 
→ Culture: Create a continuous improvement culture always consider new ideas.

6) Five Principles of Lean Manufacturing:

→ Lean Manufacturing is a continuous process improvement methodology consisting of five primary principles:
    1. Identify Value (from the customer's perspective) - Lean Manufacturing
    2. Map Value Stream (map the steps in the value stream) - Lean Manufacturing
    3. Create Flow (create a smooth flow) - Lean Manufacturing
    4. Establish Pull (the right amount pulled at the right time, no more, no less) - Lean Manufacturing
    5. Seek Perfection (elimination of all waste in the value stream) - Lean Manufacturing

Five Principles of Lean Manufacturing

7) Traditional Thinking vs Lean Thinking - Lean Manufacturing

👉 Click Here: For Traditional Thinking vs Lean Thinking - Lean Manufacturing

8) Benefits of Lean Manufacturing:

→ Main benefits of Lean Manufacturing is mentioned below:  
    1. Improved Quality
    2. Improved Visual Management 
    3. Increased efficiency
    4. Manpower and space Optimization
    5. Easier to manage any process
    6. Continuous improvement
    7. Problem Elimination
    8. On time delivery
    9. Safer Work Environment
   10. Improved employee morale
   11. Empowerment of employees

9) Commonly used Tools and Methods for Lean Manufacturing are:

  Some of the Commonly used Tools and Methods for Lean Manufacturing are:
  • 5S Methodology
  • Kaizen (Continous Improvement)
  • Lean Wastes (8 wastes)
  • PDCA Problem Solving
  • Jidoka
  • Single piece flow
  • Poka-yoke (error-proofing)
  • Pull System/Kanban (Just In Time - JIT)
  • Heijunka (leveling or balancing)
  • Takt Time
  • Andon
  • Hoshin Kanri
  • Overall Equipment Effectiveness (OEE)
  • Cellular Manufacturing
  • Total Productive Maintenance (TPM)
  • Total Quality Management (TQM)
  • Value Stream Mapping
  • SMART Goals
  • KPIs
  • Single-Minute Exchange of Die (SMED)
  • 5 Whys
  • Quality At Source
  • Process Standardization

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See Also: Lean Manufacturing
➨ 5S Methodology - A Lean Manufacturing Tool
➨ Traditional thinking Vs Lean thinking? - Lean Manufacturing
➨ Kaizen (Continous Improvement) - A Lean Manufacturing and Six Sigma Tool
➨ The 8 Wastes in Lean Manufacturing - Lean Manufacturing
➨ PDCA Cycle - A Lean Manufacturing Tool