• What Is Lean Management?

Lean management is all about the creation of value.

What is making your company revenue? Whatever is not
included in the category of creating value for the
company is considered waste. The goal is to develop
processes that are working toward continued success.
Those who believe in lean management also look at value
and progress through the eye of the customer, who is
respected as one of the most important stakeholders.
 • 5 Principles of Lean Management

•  Identify Customers and Specify Value 

• Identifying and Mapping the Value Stream
• Create Flow by Eliminating Waste
• Respond to Customer Pull
• Pursue Perfection
 TPS – Toyota Production System
PDCA – Plan Do Check Act IDEA – Investigate Design Execute
Adjust
DMAIC – Design Measure Analyze Improve Control DPMO –
Defects per million opportunities
 What is lean
BENEFITS OF THE LEAN PHILOSOPHY
One of the more interesting trends to affect profitability as
well as the way in which companies address overall
efficiency
is the concept of “Lean.”
Lean is based on two main philosophies:
1. Only do what the customer values, and
2. Relentless identification and elimination of waste.
When Lean is successfully implemented through effective
planning and implementation the following will occur:
• Reduce lead time
• Reduce work in process
• Improve quality
• Improve flexibility
• Reduce transactions
• Simplify scheduling
• Enhance communications
• Reduce costs
 BENEFITS OF THE LEAN
PHILOSOPHY
• Reduce lead time
• Reduce work in process
• Improve quality
• Improve flexibility
• Reduce transactions
• Simplify scheduling
• Enhance communications
• Reduce costs
• Improve on-time deliveries
• Increase sales
• Improve space utilization
LEAN MANUFACTURING
OVERVIEW
What is Lean Manufacturing? Lean manufacturing is
a team-based systematic approach to identifying and
eliminating wasteful or non-value-adding activities within
the manufacturing environment. It is a whole way of
thinking, and should be considered much more than a
series of programs or techniques. It must become a whole
system approach in order to create a new operating
philosophy, which focuses on eliminating all non-value adding
activities from order entry to receipt of payment.
5S
MUDA, MURA, MURI
Three terms often used together in the Toyota Production System (and called the Three Ms) that
collectively describe wasteful practices to be eliminated.

Muda
Any activity that consumes resources without creating value for the customer. Within this general
category it is useful to distinguish between type one muda, consisting of activities that cannot be
eliminated immediately, and type two muda, consisting of activities that can be eliminated
quickly through kaizen.

An example of type one muda is a rework operation after a paintbooth, which is required to obtain
a finish acceptable to the customer from a paint process that is not highly capable. Because a
completely capable paint process for fine finishes has eluded manufacturers for decades, it is not
likely that this type of muda can be eliminated quickly.

An example of type two muda is multiple movements of products and inventories between steps in
a fabrication and assembly process. These steps can be quickly eliminated in a kaizen workshop by
moving production equipment and operators into a smoothly flowing cell.

Mura
Unevenness in an operation; for example, a gyrating schedule not caused by end-consumer
demand but rather by the production system, or an uneven work pace in an operation causing
operators to hurry and then wait. Unevenness often can be eliminated by managers through level
scheduling and careful attention to the pace of work.
Suppose that a firm needs to transport six tons of material to its customer and is
considering its options. One is to pile all six tons on one truck and make a single
trip. But this would be muri because it would overburden the truck (rated for
only three tons) leading to breakdowns, which also would lead to muda and
mura.

A second option is to make two trips, one with four tons and the other with two.
But this would be mura because the unevenness of materials arriving at the
customer would create jam-ups on the receiving dock followed by too little
work. This option also would create muri, because on one trip the truck still is
overburdened, and muda as well, because the uneven pace of work would cause
the waste of waiting by the customer’s receiving employees.

A third option is to load two tons on the truck and make three trips. But this
would be muda, even if not mura and muri, because the truck would be only
partially
The Five Lean Principles Explained:
Lean Manufacturing:
Principles, Tools and
Methods
Improve productivity and increase profits through lean
manufacturing
Version
Introduction: The 9 Principles of Lean Manufacturing
1. Continuous
Flow
2. Lean Machines/
Simplicity
3. Workplace
Organization

4.Parts
Presentation
5. Re configurability

6.
Product
Quality
7. Maintainability

8. Ease of Access

9. Ergonomics