is lean manufacturing?
What is lean
manufacturing all about? Very simply put, the lean manufacturing process is a comprehensive way to reduce waste of
all types. It could be a waste of time or material, it is still waste.
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This course provides learners with a
comprehensive understanding of how Lean Manufacturing works in a manufacturing company.
Lean concepts (why lean, lean terminology, identifying wastes, Value Stream Mapping methods and
the linkage between lean and Six Sigma) and lean practices (streamlining the value stream,
workplace organization, ensuring predictability and consistency, set-up reduction, TPM, the
visual workplace and continuous improvement) are covered. The course provides the learner with
lean implementation suggestions including approaches for addressing people issues, collecting
and analyzing data to plan and track lean efforts, process workflow and layouts options with
rationale and a sequential roadmap.
Many studies have measured the amount of waste a typical manufacturer has, and it is usually
shocking, as well as revealing.
It takes time and a lot of effort to change a shop culture. It is not enough to add slogans and
banners, or even add one program after another. Lean manufacturing is like adding spokes to a wheel, so the wagon
Learn what it is, how to put it all together in a comprehensive, integrated plan. You must avoid the mistake of
piecemealing your program together with related, but disconnected techniques. Lean is an ongoing process.
Integrate your approach to lean
Probably one of the easiest lean manufacturing processes to implement. It gets everyones attention,
provides immediate benefits and "makes sense" to almost anyone.
5S does not require a lot of training, you might not even need a consultant to get started. There
is a great deal of training material available online, such as powerpoint presentations, videos, ebooks, and
software to provide methods and examples.
You might like it so much you will want to do it at home!
This is Toyota's famous tool for continuous improvement. The idea is that everyone in the
organization re-examines their work and improves it in small ways within their control.
Mini-Kaizens are like raindrops that add up to make a flood. This lean concept is quite useful and
easy for management to implement.
Value Stream Mapping
Learn how to identify those areas that are producing waste and develop a map to improve, using lean
manufacturing methods. Once learned, this becomes an internal process that changes the work environment
Many companies have used this concept to learn just where they currently are, and how to get where
they want to be. A great solution that can get people involved.
This is a method that enables you to measure your processes in order to improve your bottom line.
Once you get things organized, decide to continuously improve your processes, and identify areas of waste, you need
a way to monitor your progress.
This engineering system keeps you on-track by monitoring your processes. You use real-time examples
from your own company to create track your programs.
How do you begin the lean manufacturing
Everyone in the
organization will require significant training. You will need to develop an overall strategy and training plan
and recognize that this is a major commitment from the management down to the lowliest employee.
A step by step approach would approximate this plan, depending on your specific needs. Here are 6
steps to implement lean manufacturing.
||Determine which aspects of lean
manufacturing apply to you, prioritize according to your needs and abilities
||Categorize your people into groups
according to similar training needs
||Identify your programs and make a
matrix, or chart
||Decide whether you will hire an
consultant or do it in-house
||Develop a time frame or schedule
according to work area or personnel
||Prepare an immediate schedule and
If you want to learn how to use the lean process, I highly recommend the Lean Manufacturing web-based training
course. You will get a thorough understanding of all the components of lean manufacturing, including Value Stream Mapping, six sigma, 5S and much more.
More great ideas on lean manufacturing