Lean Manufacturing | What is Lean Manufacturing?

Lean Manufacturing | What is Lean Manufacturing? | What is Lean Process? 

What is Lean Manufacturing?

→ Lean Manufacturing is all about the optimizing processes and eliminating waste and we will become more efficient in our manufacturing.
→ In this concept, we have to find waste in our process and cut it out and the process will become lean.
→ It is a systematic approach to identifying and eliminating waste through continuous improvement in our process.
→ Lean Manufacturing is a Japanese concept.
→ It is a methodology that focuses on minimizing waste within manufacturing systems and simultaneously it maximizes productivity.
Elephant with fat in Lean Manufacturing

Elephant without fat in Lean Manufacturing

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

➤ History of Lean Manufacturing:

→ The Milestone wise history is mentioned below:

History of Lean Manufacturing

➤ 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....

8 Wastes in Lean Manufacturing:

→ The 8 Wastes are: Acronyms - TIMWOODS

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

(2) Inventory Waste:
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:
Do people and equipment move between tasks efficiently?

(4) Waiting waste:
How much time is consuming between your production steps? Does someone have to wait for someone else to finish a task?

(5) Over Production:
Are you producing the right amount of product to meet your consumers' demand?

(6) Over Processing waste:
Do you work on the product too many times?

(7) Defects waste:
How much time do you spend finding and fixing production mistakes?

(8) Skills sets (non-utilized talent) waste:
Do you use workers efficiently?

8 lean wastes in lean Manufacturing

➤ The Key Points in Lean Manufacturing:

→ Teamwork: Team Formation, people are used to doing the work
→ Observe: Analyse the current situation
→ Ideas: The team develops ideas by brainstorming - Ideas related to eliminate the waste.
→ Communication: By any modes of communication, the team is informed about the goals, any changes, the progress of the project, etc.
→ Culture: Create a continuous improvement culture surround the workplace.

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)
    2. Map Value Stream (map the steps in the value stream)
    3. Create Flow (create a smooth flow)
    4. Establish Pull (the right amount pulled at the right time, no more, no less)
    5. Seek Perfection (elimination of all waste in the value stream)

Five Principles of Lean Manufacturing

➤ Traditional Thinking vs Lean Thinking:

➤ Benefits of Lean Manufacturing: 

  • Improved Quality
  • Improved Visual Management 
  • Increased efficiency
  • Manpower and space Optimization
  • Easier to manage any process
  • Continuous improvement
  • Problem Elimination
  • On-time delivery
  • Safer Work Environment
  • Improved employee morale
  • Empowerment of employees

Commonly used Tools and Methods:

  Some of the Commonly used Tools and Methods of Lean Manufacturing are: