What 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.

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 can roll.

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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 manufacturing

 5S  

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!

 Kaizen

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 permanently.

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.

 Six Sigma

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 process?

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 begin!

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.

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