What Is Lean Manufacturing? Top Tips for Cutting Costs



It is a proven Lean Manufacturing for improving profits by pursuing perfection. It also allows us to draw comparisons among all processes, and tells how good a process is. 7.Motion—any motion that employee has to perform that does not add value to the product is considered unnecessary. 14-day free trial and find out why thousands of manufacturers use it to optimize their business operations. For instance, during high economic growth, customer preference could shift towards buying premium products with better finishing and packaging. Although applying the first four principles can provide a great boost to your business, the pursuit of perfection is what will set you apart.

Within this process enterprises must be able to integrate a multitude of technological, organizational and managerial viewpoints. The paper reviews 209 research papers for their research contribution, research methodology, author profile, type of industry, and tools/techniques/methodology used. This paper highlights various definitions by various researchers and practitioners.

Agile manufacturing

Kitting is the process of having a supplier assemble all the parts and materials needed for a particular task into a single kit and giving the kit a single stock-keeping unit code. Kitting ensures all the parts needed to complete a manufacturing task are present at the point of production, with all quality checks and quantities verified. It has become an internal and external supply chain initiative, requiring good relationships with suppliers and customers, a stable work schedule, frequent small purchases, and commitment from all stakeholders in the process. The Gemba walk uses a Japanese term meaning ‘the real place,’ which refers to where the real work is happening. The Japanese designed the concept to get executives out of their offices and engage with the workers to build relationships and understand what problems they might be experiencing in meeting production needs.

A successful operation depends on a company having regular outputs, high-quality processes, and reliable suppliers. Organizations looking to improve their processes to incorporate lean manufacturing should first look to technology and training. Using purpose-built enterprise resources planning software to track inventory waste can help advance supply and demand planning. As you can see, there are many lean manufacturing concepts and techniques you can apply to eliminate waste and create an efficient and lean production environment. Review available lean production methods and choose the ones that are most appropriate for your niche and your business.

7 Manufacturing performance improvement through lean production

The Author has more than 25 years experience of working in the Automotive, construction and Consulting Industries in Lean Manufacturing, six sigma, quality management and other business improvement techniques and philosophies. Rather than plan and push production through your processes you pull products from the processes as they are ordered. We implementKanbanto enable clear flow without excessive amounts of planning or inventory. These maps and charts allow you to quickly identify where you need to make improvements within your processes.

What are the 5S’s of lean manufacturing Six Sigma?

The five words in 5S represent the five steps to accomplish this goal. They are sort, set, shine, standardize and sustain. Lean bases the words on the original Japanese: seiri, seiton, seiso, seiketsu and shitsuke.

Previously a textile company, Toyota moved into building automobiles in 1934. Kiichiro Toyoda, founder of Toyota Motor Corporation, directed the engine casting work and discovered many problems in their manufacturing, with wasted resources on repair of poor-quality castings. Manufacturing efficiency can help reduce the strain that production places on the environment. This is why constantly analyzing and modeling data is so important, as organizations can identify ways to limit their consumption of energy, raw materials and more. Following lean manufacturing principles can lead to numerous benefits that can help organizations ensure the future success of their operations, but positive growth always requires a degree of discomfort. As such, there are both advantages and disadvantages to implementing a lean manufacturing strategy.


Jidoka uses automation to detect an abnormal manufacturing process, immediately stopping production. The technique emerged from the Japanese textile industry, where a textile loom was invented that stopped the loom when the shuttle thread broke. Previously, when the thread broke, the loom would continue manufacturing defective fabric, requiring one operator to watch each loom. The system requires other operators, team leaders, or managers to go to the workstation and address the problem immediately. Pull cords or buttons can manually activate the system or be automatically generated by logic controllers, streamlining the LOTO process.

It is a philosophy that should be rooted in your company culture, communicated to every worker, and be the foundation for your operation. Give frontline workers mobile communication tools to connect with the company. They often spend over three hours a week just searching for information. A mobile collaboration platform can eliminate that wasted time and energy by giving them access to all of the information they need to perform their jobs. Use mobile communication tools to invest in job training programs. This creates opportunities for your workers to grow and build up their strengths for both their personal gain and to create greater value in your operation.

Lean Production

But when sales exceed forecasts, it can be difficult for production to keep up. Conversely, when demand doesn’t meet supply, profitability suffers. It’s worth noting that what your company thinks is valuable and what your customers actually value may be different things.

meet customer

Managers are encouraged to spend time at gemba because lean thinking demands hands-on decision making. It is one of the core lean manufacturing concepts and is highly important for effective waste elimination. The term Lean manufacturing refers to the application of Lean practices, principles, and tools to the development and manufacture of physical products. Many manufacturers are using Lean manufacturing principles to eliminate waste, optimize processes, cut costs, boost innovation, and reduce time to market in a fast-paced, volatile, ever-changing global marketplace. Eliminate functional barriers and identify ways to improve lead time. This aids in ensuring the processes are smooth from the time an order is received through to delivery.


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