Lean Manufacturing | Principles | Tools | Examples | PDF

What is Lean Manufacturing?

→ Lean is all about optimizing processes and eliminating waste.

→ By implementing this methodology we will become more efficient.

→ This is a Japanese concept; 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 is a culture, a philosophy, a mindset, a way of life.

Table of Contents:

• What is Lean Manufacturing?
• History of Lean Manufacturing
• Goals of Lean Production
• Strategies of Lean Manufacturing
• Eight Wastes of Lean Manufacturing
• Lean Manufacturing Principles
• Lean Manufacturing Implementation Examples
• Lean Manufacturing Tools
• Benefits of Lean Manufacturing
• Conclusion

History of Lean Manufacturing:

→ It is a production methodology that focuses on minimizing waste.

→ Also it maximizes productivity.

→ Implementing a lean process and system, uses less of everything than traditional mass production.

⏩Examples of less consumption in the lean process are:

• Less waste
• Less human effort
• Less manufacturing space
• Less investment in tools
• Less inventory
• Less engineering time to develop a new product, etc.

→ It originated in the mid-20th century, primarily in Japan.

→ After that it was widely adopted by different businesses and organizations across the world.

⏩Refer to the below mentioned a brief history:

• Year 1798: Eli Whitney - Developed Interchangeable Parts.
• Year 1913: Henry Ford - Developed the Moving Assembly Line
• Year 1798: Sakichi Toyoda - Develops 5 Whys & Mistake Proofing
• Year 1920's: Toyota Motor Company - Toyota Motor Company Established
• Year 1950: Dr. Deming - Introduced Lean Quality Principles
• Year 1950's: Taiichi Ohno - Developed The Toyota Production System (TPS)

→ Toyota Production System is also known as "The Toyota Way."

Goals of Lean Production:

• Cost Reduction
• Creating Conditions for Improving Product Quality
• Quality First Time Through
• Customer Satisfaction
• Building In Quality at Each Stage
• The Added Value of Repairs
• Motivate all workers toward continuous improvement
• Streamline or smooth operation flow etc...

➡️ Sample Presentation File

➡️ WhatsApp Us to Get this Presentation Bundle

➡️ Mail us to Get this Presentation Bundle

Strategies of Lean Manufacturing:

• Housekeeping
• Make it right the first time
• Setup time reduction
• One-piece flow rather than the lot
• Bottleneck elimination and line balancing
• Skill diversification and multi-tasking workers
• Visual management
• Preventive maintenance
• Fitness for use
• Compact plant layout and product-oriented design
• Streamlining of materials handling
• Small group improvement activities
• Cellular manufacturing
• Pull system
• Kanban system

Eight Wastes of Lean Manufacturing:

→ In manufacturing or service, waste is defined as any activity that does not add value to the product or service to the customer.

→ Originally, the Toyota Production System identified seven wastes.

→ These wastes are known as Muda.

→ Later on one more waste is added to these seven wastes and that is skill set waste.

→ This focuses on the importance of utilizing human potential.

⏩The Eight Lean Wastes (TIMWOOD) are:

1. Transport
2. Inventory
3. Motion
4. Waiting
5. Overproduction
6. Overprocessing
7. Defects
8. Skills (Unused Talent)

👉 Read our detailed article on Eight Lean Wastes with Case Study.

Additional Wastes of Lean:

→ Above we have seen the eight wastes, adding to those some more wastes are also available that are mentioned below.

⏩Additional Wastes are:

→ Faulty or defective goods

→ Waste of skills

→ Under-utilizing capabilities

→ Assigning tasks without proper training

→ Underutilization of automation and systems

→ Goals and objectives are not communicated

Lean Manufacturing Principles:

→ Lean is a systematic approach to eliminating waste within a system or process.

→ It ensures good productivity and quality.

→ It was primarily derived from the Toyota Production System.

→ Toyota Production System (TPS) focuses on maximizing value for customers through efficient processes.

⏩Lean is a Culture that Focuses on:

• Continuous Improvement
• Open Minded Thinking
• Challenging the Norm

⏩Five Fundamental Principles of Lean Manufacturing are:

1. Identify Value
2. Map Value Stream
3. Create Flow
4. Establish Pull
5. Seek Performance

👉 Read our detailed article on Five Lean Principles with Case Study.

Lean Manufacturing Implementation Examples:

→ Examples of lean implementation can be found in various industries such as automotive, electronics, healthcare, and even service sectors.

→ Now we will learn about the different examples of implementation of lean principles:

Example 01: Toyota Motor Corporation (Automotive)

→ Toyota Motors has invented the Toyota Production System (TPS).

→ Toyota Production System is the foundation of Lean Manufacturing.

→ It emphasizes Just-in-Time (JIT) production and continuous improvement (Kaizen).

→ Toyota uses a Kanban system to manage inventory.

→ Parts are produced or ordered only when needed, based on customer demand.

→ It minimizes excess inventory and reduces waste.

→ Employees are inspired to identify inefficiencies and suggest improvement opportunities.

→ That will create a culture of continual improvement.

→ By implementing the above principles Toyota has maintained high levels of quality, minimized production costs, and quickly fulfilled the market demands.

Example 02: Nike (Apparel and Footwear)

→ Nike has implemented Value Stream Mapping, JIT, and Flow.

→ Nike restructured its supply chain using Lean principles to reduce waste and increase efficiency.

→ They applied Value Stream Mapping to identify bottlenecks and non-value-added steps in their production process.

→ By implementing lean principles Nike significantly reduced lead times, improved inventory management, and cut costs while maintaining high product quality.

→ All the above benefits help Nike with sustainable manufacturing and improved customer satisfaction.

Example 03: Intel (Semiconductor Industry)

→ Intel has implemented Flow, Value Stream Mapping, and Kaizen.

→ Intel implemented lean principles to improve the production of semiconductors.

→ In this industry, precision and speed are critical.

→ Intel streamlined its production lines, improved equipment utilization, and applied continuous improvement to reduce defects and cycle time.

→ By implementing the above principles, Intel reduced production cycle times by over 50%, cut down waste, and improved product quality.

→ Also get benefits of faster product launches and cost savings.

Lean Manufacturing Tools:

→ There are many lean tools that are used for different purposes.

⏩Most common lean tools are:

• 5S Methodology
• Kaizen (Continous Improvement)
• PDCA Problem Solving
• Jidoka
• Single piece flow (One 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)
• SMART Goals
• Key Process Indicators (KPIs)
• Single-Minute Exchange of Die (SMED)
• 5 Whys | Why Why Analysis
• Quality At Source
• Process Standardization
• Six Big Losses Analysis
• Bottleneck Analysis
• Gemba
• VSM Study

Benefits of Lean Manufacturing:

→ Improve Quality and Visual Management

→ Increase efficiency and easy to manage any process

→ Manpower and space Optimization

→ Continuous improvement

→ Problem Elimination and on-time delivery

→ Safer Work Environment

→ Improved employee morale

→ Empowerment of employees

→ Create a more flexible and responsive production system

Conclusion:

→ Lean Manufacturing is a highly effective methodology for improving manufacturing and service efficiency.

→ Also we can get benefits such as reducing waste and enhancing product quality.

→ Focusing on the continuous elimination of non-value-added activities promotes a culture of continuous improvement.

⏩Many businesses get different benefits by implementing lean such as:

• Lower manufacturing costs
• Faster production times
• Better customer satisfaction
• Increased flexibility to fulfill market demands

→ The success of Lean Manufacturing depends on a strong organizational and leadership commitment and a long-term business vision.