Lean Manufacturing

Definition
Lean Manufacturing A way to eliminate waste and improve efficiency in a manufacturing environment.

5 principles of Lean Value - specify what creates value from the customers perspective. The value stream identify all the steps along the process chain. Flow - make the value process flow. Pull - make only what is needed by the customer (short term response to the customers rate of demand). Perfection - strive for perfection by continually attempting to produce exactly what the customer wants.
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How does Lean work?

Considers an end to end value stream that delivers competitive advantage. Seeks fast flexible flow. Eliminates/prevents waste (Muda). Extends the Toyota Production System (TPS).

Lean The Toyota Production System

Based on two philosophies: 1. Elimination of waste 2. Respect for people Toyota Production Systems - Four Rules 1. All work shall be highly specified as to content, sequence, timing, and outcome. 2. Every customer-supplier connection must be direct, and there must be an unambiguous yes-or-no way to send requests and receive responses. The pathway for every product and service must be simple and direct. Any improvement must be made in accordance with the scientific method, under the guidance of a teacher, at the lowest possible level in the organization.
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3. 4.

Taiichi Ohnos 7 Wastes (muda)

Overproduction Producing more than the customer orders or producing early. Inventory of any kind is usually waste. Queues Idle time, storage, and waiting are wastes Transportation Moving material between plants, between work centers, and handling more than once is waste Inventory Unnecessary raw material, work-in-process (WIP), finished goods, and excess operating supplies Motion Movement of equipment or people Over processing Work performed on product that adds no value Defective product Returns, warranty claims, rework and scrap 5