Lean Manufacturing

Lean Manufacturing - A Strategy

Lean manufacturing is a management philosophy focusing on reduction of the seven wastes.

1).  Over-production

2).  Waiting time

3).  Transportation

4).  Processing

5).  Inventory

6).  Motion

7).  Scrap

All have potential application in manufactured products or any type of business.

By eliminating waste, quality is improved, production time and costs are reduced.

To solve the problem of waste, Lean Manufacturing has several "tools" at its disposal. These include constant process analysis, "pull" production and mistake-proofing.

Most experts now agree, however, that Lean Manufacturing is not just a toolset. Rather it is a holistic, comprehensive, enterprise-wide program designed to be integrated into the organization's core strategy. In addition, experts in this field believe that philosophy-based Lean Manufacturing strategy is the most effective way to launch and sustain lean activities.

The so called "Toyota Way," popularized by Dr. Jeffrey Liker's book of the same name, emphasizes the creation of the right kind of environment in which to grow and support Lean Thinking.

Key lean manufacturing principles include:

1).  Pull processing: products are pulled from the consumer end, not pushed from the production end

2).  Perfect first-time quality - quest for zero defects, revealing & solving problems at the source

3).  Waste minimization – eliminating all activities that do not add value & safety nets, maximize use of scarce resources (capital, people and land)

4).  Continuous improvement – reducing costs, improving quality, increasing productivity and information sharing

5).  Flexibility – producing different mixes or greater diversity of products quickly, without sacrificing efficiency at lower volumes of production

6).  Building and maintaining a long term relationship with suppliers through collaborative risk sharing, cost sharing and information sharing arrangements.

Lean is basically all about getting the right things, to the right place, at the right time, in the right quantity while minimizing waste and being flexible and open to change.