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