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PrinciplesofLeanThinkingRevD2004

PrinciplesofLeanThinkingRevD2004

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Principle of lean management
Principle of lean management

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Published by: joydeep on Jan 06, 2009
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08/12/2012

 
 
Principles of Lean Thinking
Tools & Techniques
 
for
 
Advanced Manufacturing
 
July 2004Revision D
 
 
Table of Contents
 
 1
Background of Lean Thinking
Lean Thinking
is a highly evolved method of managing an organization to improve theproductivity, efficiency and quality of its products or services. Japanese and American managementspecialists developed the ideas and methods over the latter half of the last century. These managementtechniques have been employed both in the aerospace industry (Boeing) and in the auto sector (Toyota).In the manufacturing sector, the concept is sometimes referred to as World Class manufacturing or HighPerformance Manufacturing. Lean Thinking is best illustrated by using the manufacturing example.
Lean Manufacturing
is derived from the methods of the successful Japanese automobilemanufacturer, Toyota. Lean Manufacturing became internationally recognized as a result of the book,
The Machine That Changed The World,
by James Womack and Dan Jones. The focus at Toyota,according to Taiichi Ohno, was “the absolute elimination of waste,” where waste is anything that preventsthe value-added flow of material from raw material to finished goods. A firm’s customers are the final judges as to whether or not the firm has created value. The Lean approach leads its practitioners toimprove their organizations by focusing on the elimination of any and all
waste 
. Lean focuses onimprovement and advocates techniques to control the flow of material on the shop floor. As companiesimplemented Lean in North America, there were many variations of the same theme, but a number ofprinciples were generally agreed upon.1. The batch-and-queue mode of operation, which encourages large-batch processing andfocuses on the efficiency of individual machines and workers, was an outdated model.2. Lean manufacturing, which views continuous, one-piece flow as the idea, and emphasizesoptimizing and integrating systems of people, machines, materials, and facilities, can lead tosignificant improvements in quality, cost, on-time delivery, and performance.3. Lean manufacturing is fundamental transformation of an enterprise and needs to beapproached as a total organizational and cultural transformation.Lean tools in manufacturing, such as Value Stream Mapping, Quick Changeover/SetupReduction, Single Minutes Exchange of Dies (SMED), Kaizen, Cellular/Flow Manufacturing, VisualWorkplace/5S Good Housekeeping, Total Productive Maintenance (TPM), and Pull/Kanban Systems, areused to produce change. Companies and organizations employing these lean tools report significantgains in productivity and overall effectiveness within their specific entities.
Lean Manufacturing
“uses less of everything compared with mass production – half the humaneffort in the factory, half the manufacturing floor space, half the investment in tools, half the engineeringhours to develop a new product in half the time. Also it requires keeping far less than half the needed

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