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Lean Manufacturing is often referred to as the TPS (Toyota Production System), since Toyota introduced the concept of “Toyotism”. Lean focuses on eliminating waste in processes so that a higher percentage of value is produced from production effort. The Lean method leads to bigger sales revenues and at the same time brings down operating costs. The delivery performance is improved and as a result of this, enhances client contentment and relationships with suppliers. Using Lean production method, we can minimize costs in inventory, warehouse space and better quality can be achieved. It is relevant to manufacturing as well as service industry.
Lean method follows the principle of 5S, where 5S stands for sort, straighten, shine, standardize, and sustain the factory floor so that waste materials and equipment are removed from production spaces. In the standard phase of Lean 5S, routine cleaning becomes a part of everyday life, which is termed as Shitsuke. Some companies name their program as 6S, this s stands for safety, but safety actually intertwines with every phase of 5S. A workplace that is clean is a safer work area. The lean organizations are improving their processes continuously, and further improving the product qualities.
Eliminating Seven Wastes:
Lean method focuses on eliminating the following seven types of wastes. The seven elements are excess production, transportation, too much processing, inventory, waiting time, shortcomings and scrap/waste items. This means that we can eliminate or at least minimize the above mentioned seven different types of wastes, thereby increasing the productivity of the overall organization. When manufacturing companies implement Lean production systems, manufacturing time is considerably reduced. All forms of waste, distractions and unethical behaviour are eliminated and workers do their jobs without interruptions. Thus, the overall efficiency gets increased, and hence increases the profit of the organization.
Lean optimises workflow and eliminates waste through employee involvement and continuous improvement, taking care of customer’s value and interests. The lean production system is geared towards simplification and elimination of wastes. Following the principles of Lean 5S and elimination of seven wastes strategies, we can thereby increase the overall productivity and profit of an organization.