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Lean Manufacturing
 

Lean manufacturing 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 made Lean a hot topic in management science. In order to improve overall customer value, the Lean approach focuses on the reduction of the original Toyota 8 wastes.



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%


Lean manufacturing

Lean and DMAIC picture above from Lean Sigma Institute
 



Five principles of lean:
 

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

Principle 2: Identify the value stream for products and services and remove any non-value-added 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 from the customer.
 

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



Lean Tools
 

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. Below is a picture and links to some of the common Lean Tools.
 

Lean manufacturing
 

5S-visual-management

Kanban

Level-Mix

Mistake-proofing

One-Piece-Flow

Quick-Changeover

Standard-Work

value-stream-mapping

FMEA

Lean Thinking

Overall Equipment Effectiveness

SMED

Spaghetti

Takt Time

Theory of Contraints

Total Productive Maintenance

Value Stream Mapping

Table of Waste Categories



Another Lean Approach


There is a second approach  to Lean Manufacturing that is promoted by Toyota. This focuses's upon implementing the smoothing the flow (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.
 

After leaning about Lean manufacturing click here to see other process improvement tools.
 

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