lean manufacturing is a management model that focuses on minimizing losses in manufacturing systems while maximizing value creation for the end customer. To do this, it uses the minimum amount of resources, that is, those strictly necessary for growth.
Creating flow focuses on reducing the eight types of “waste” into manufactured products: 2
- Wait time.
- Excess of procedures.
- Don’t use people’s creativity.
Eliminating waste improves quality and reduces production time and cost. Lean tools (in English , ‘agile’, ‘lean’ or ‘without fat’) include continuous processes of analysis (called kaizen in Japanese ), pull production (‘deterrence and incentive’, in the sense of the Japanese term kanban ), and “fail-safe” elements and processes ( poka yoke , in Japanese), with the philosophy of Monozukuri (‘do things right, in Japanese), all from the Japanese genba or area of value.
Crucially, most costs are calculated at the design stage of a product. Often an engineer will specify known and safe materials and processes at the expense of cheap and efficient ones. This reduces the risks of the project, or what is the same, the cost according to the engineer, but by increasing the financial risks and reducing the benefits. Good organizations develop and review checklists to validate product design.
The key principles of Lean Manufacturing are:
- Perfect quality first time: search for zero defects, detection and solution of problems at their source.
- Minimization of waste: elimination of all non-value-added activities and safety nets, optimization of the use of scarce resources (capital, people and space).
- Continuous improvement : reducing costs, improving quality, increasing productivity and sharing information.
- Processes “pull”: products are pulled (in the sense of requested) by the end customer, not pushed by the end of production.
- Flexibility: quickly produce different mixes of a wide variety of products, without sacrificing efficiency due to lower production volumes.
- Building and maintaining a long-term relationship with suppliers by taking agreements to share risk, costs and information.
What does Lean manufacturing mean?
The term Lean manufacturing refers to the application of Lean practices, principles, and tools to the development and manufacture of physical products. … Manufacturers use Lean manufacturing principles to eliminate waste, optimize processes, cut costs, and boost innovation in a volatile market.
What Kaizen means?
change for the better Kaizen is a Japanese term meaning “change for the better” or “continuous improvement.” It is a Japanese business philosophy regarding the processes that continuously improve operations and involve all employees. Kaizen sees improvement in productivity as a gradual and methodical process.
How can I practice lean manufacturing?
- Identify value. This means thinking about the end customer and what they deem valuable.
- Map the value stream. Layout all the steps within your process and get rid of those that don’t add value.
- Create flow. …
- Establish pull. …
- Strive for perfection.
What are the 7 key elements of lean manufacturing?
- Over Production.
- Waste of Unnecessary Motion.
- Waste of Inventory.
- Production of Defects.
- Waste of Waiting.
- Waste of Transportation.
- Waste of Overprocessing.
- Continuous Improvement (commonly referred to by the Japanese word kaizen) is arguably the most critical principle of lean manufacturing.