Lean Manufactering
María F. Arango
Unidad Central Del Valle Del Cauca
Engineering Faculty
Program: Industrial Engineering
April 2023
Lean Manufacturing
1. Types de Muda
Fuente: Autor (2025).
2. Implementing Lean interventions involves a structured approach rooted in
continuous improvement and customer value. Here are the key steps and principles
that guide the Lean transformation journey.
Define Value from the Customer's Perspective
The Lean journey begins by clearly identifying what constitutes value for the customer.
This means understanding what the customer is willing to pay for and focusing all
efforts on enhancing that value while eliminating anything that does not contribute to it.
Map the Value Stream
Create a detailed map of all steps involved in the production process. This "value
stream mapping" helps visualize both value-added and non-value-added activities. It
exposes areas of waste (Muda) and sets a foundation for targeted improvements.
Establish Flow
Once waste is identified and eliminated, the next step is to ensure that processes flow
smoothly without interruptions. One-piece flow is a Lean principle that aims to move
products through the production cycle one unit at a time, reducing lead time,
bottlenecks, and work-in-process inventory.
Implement Pull Systems
Instead of pushing products based on forecasts, Lean systems operate on a pull basis—
only producing what is needed, when it is needed, and in the amount needed. This
minimizes overproduction and reduces excess inventory.
Pursue Perfection through Continuous Improvement (Kaizen)
Lean is not a one-time initiative but a continuous journey. Teams are encouraged to
regularly analyze processes and make incremental improvements. Kaizen promotes
small, consistent changes that cumulatively result in major performance enhancements.
Standardize Work
Once best practices are identified, they must be standardized across the organization.
Standardized work ensures consistency, simplifies training, and provides a baseline for
future improvements.
1. Engage and Empower Employees
People are the heart of Lean. Workers closest to the process often have the most valuable
insights. Lean organizations create a culture where every employee contributes ideas,
solves problems, and feels ownership of the process.
2. Use Visual Management Tools
Tools like Kanban boards, Andon systems, and visual work instructions make process status
visible in real-time. This transparency enhances communication, facilitates quick responses
to problems, and supports continuous improvement.
3. Eliminate the Eight Wastes (DOWNTIME)
A core principle of Lean is the elimination of the eight types of waste: Defects,
Overproduction, Waiting, Non-utilized Talent, Transportation, Inventory, Motion, and
Overprocessing. Systematically removing these inefficiencies leads to faster, more reliable
processes.
4. Focus on Long-Term Thinking
Lean is not just a set of tools; it is a mindset. Organizations must commit to long-term
improvements and align strategies, leadership, and culture around Lean principles to
achieve sustainable success.
By following these structured steps, an organization can successfully initiate Lean
interventions, significantly improve efficiency, reduce costs, and enhance customer
satisfaction. These principles apply not only in manufacturing but across service industries,
healthcare, and more, demonstrating Lean’s versatility and enduring relevance.
