Lean manufacturing

 

Lean manufacturing picture above from leansigmainstitute

 

What is Lean ?

1- Eliminate waste and non-value-added activity (NVA).

2- Develop Lean thinking within your team.

 

Lean manufacture is a generic process management philosophy derived mostly from the Toyota Production System (TPS) but also from other sources.

 

Toyota's steady growth from a small player to the most valuable and the biggest car company in the world has focused attention upon how it has achieved this, making "Lean manufacturing "a hot topic in management science in the first decade of the 21st century.

It is renowned for its focus on reduction of the original Toyota 8 wastes in order to improve overall customer value.

 

What Is Lean benefits?

 

Lean benefits
Element	Benefit
Capacity	10 to 20% gains in capacity by optimizing bottlenecks
Inventory	Reductions of 30 to 40% in inventory
Cycle time	Throughput time reduced by 50 to 75%
Lead time	Reduction of 50% in order fulfillment
Product development time	Reductions of 35 to 50% in development time
Space	35 to 50% space reduction
First-pass yield	5 to 15% increase in first-pass yield
Service	Delivery performance of 99%

 

There is a second approach  to Lean Manufacturing that is promoted by Toyota in which the focus is upon implementing the 'flow' or smoothness of work (opposite of mura, unevenness) through the system and not upon 'waste reduction'.

Techniques to improve flow include production leveling, "pull" production (by means of kanban) and the Heijunka box.

 

The difference between these two approaches is not the goal, but the prime approach to achieving it.

 

Five principles of lean:

 

Principle 1: Accurately specify value from the customer's perspective for both products and services.

Principle 2: Identify the value stream for products and services and remove non-value-adding waste along the value stream.

Principle 3: Make the product and services flow without interruption across the value stream.

Principle 4: Authorize production of products and services based on the pull by the customer.

Principle 5: Strive for perfection by constantly removing layers of waste.

 

Lean Tools

 

For many, Lean is the set of  'tools' that assist in the identification and steady elimination of waste (muda), the improvement of quality, and production time and cost reduction.

To solve the problem of waste, Lean Manufacturing has several 'tools' at its disposal.

These include continuous process improvement (kaizen), "5 Whys"  the and mistake-proofing (poka-yoke).

In this way it can be seen astaking a very similar approach to other improvement methodologies.

 

Some of lean tools you can use

 

• 5S-visual-management

• Kanban

• Level-Mix

• Mistake-proofing

• One-Piece-Flow

• Quick-Changeover

• Standard-Work

• value-stream-mapping

• FMEA

Lean manufacturing update

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lean principles 
I’d like to know is there standard for lean principles, techniques and tools?

In some sites read about standard SAE J4000, 4001, but I don’t know how ...

3 C'S - Concern, Cause, Countermeasure 
A good author of books is John Oakland whom is an expert on TQM systems and