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WHAT IS lean MANUFACTURINGThe core idea of lean production is rather simple: relentlessly occupational on eliminating waste indigenous the production process.
What is waste? It can take countless forms, but the underlying idea is to remove anything and also everything the does not include value native the view of her customer.
Another means to look in ~ lean production is together a arsenal of tools, techniques, and principles that have been proven to be efficient at control waste the end of the production process.
For this topic, us will discover the significance of lean from 2 perspectives:Five lean Principles: The classic procedure for implementing lean.Seven fatal Wastes: The timeless categories of garbage in production processes.
The essence of lean manufacturing is caught by the five Lean ethics (outer ring) and also the 7 Deadly Wastes (center circle).
FIVE skinny PRINCIPLES
What room the 5 Lean Principles?The 5 Lean principles are a proven methodology for integrating lean into your manufacturing process. These values are effective due to the fact that they help you:Look in ~ your process from the perspective of your customer and also identify what castle deem valuable.Distinguish procedures and activities in the process that carry out value from those that produce waste.Streamline the process to be free of bottlenecks and delays. Align to customer demand and adjust quickly to transforms in the demand.Promote one internal culture of consistent improvement and also excellence.
The end result will be much better value for your customers, decreased waste, enhanced productivity, an benefit over your competition, and, ultimately, bigger profits.
Let’s review each of the 5 principles.
Identify and also Define Value
Value is characterized in the paper definition of the products and/or solutions that you provide for her customers:What do your customers truly want?What room they ready to salary for?What do they perceive together valuable?
As you deserve to see from this questions, value is characterized purely indigenous the customer perspective. In other words, the goal is to recognize your customer’s demands - both clear (stated) and also implicit (unsaid). That’s why we recommend that you go beyond direct customer feedback (reactive) and conduct your very own research (proactive).
If you execute not manufacture directly for end customers, girlfriend can take into consideration your client to be the different segments of her ultimate market.
Map the value Stream
Once you have a an excellent understanding of what her customers value, recognize the actions (and the activities within the steps) in your procedure that create and reinforce this worth (productive) matches the procedures and activities that execute not create and reinforce this worth (wasteful). This is known as value stream mapping.
More specifically, value stream mapping articulates the current and future says of processes in a means that highlights methods for improvement. Native an agile perspective, it provides you with a roadmap for development that will help you come iteratively reach a preferred future state.
To map a value stream, identify every step in the whole manufacturing process, from upstream it is provided to downstream delivery. The much more care you take it in accurately identifying and also characterizing each step, the more opportunities friend will have to improve.
Once the process is mapped into steps, ask the adhering to three concerns for every step:Does this step, and also its activities, bring value to the customer?Does this step, and also its activities, move your product or organization downstream towards the customer?Does this step, and also its activities, flow smoothly, without impediments, within the context of the worth stream?
These questions will assist you differentiate between value and also waste. Special, categorize each step, and its activities, indigenous the perspective of worth (and waste).
|Add Value?||The customer is ready to pay because that this work. No immediate activity is required.|
|Create necessary Waste?||The client would choose not come pay because that this work. This task does no directly include value but is important to ensure the your last product or organization is valuable. Effort to minimization this activity.|
|Create Unnecessary Waste?||The client is no willing to pay because that this work. This activity does not add value. Strive to totally remove this activity.|
Create Smooth Flow
Now that you have a much much better understanding that the steps and tasks of your manufacturing process, you room in a far better position to develop a smoothly flowing process - ideally one i beg your pardon is totally free of bottlenecks, inventory, and delays.
Examples of strategies to improve circulation include:Reduce Changeover Times: making it quicker to switch between products so you deserve to be an ext responsive to her customers.Avoid Batch Operations: batching is the contrary of flow and inherently create bottlenecks, queues and inventory.Organize Equipment: to enhance the natural circulation of the value stream so flow is natural in your process.
Enabling your commodities and/or services to circulation smoothly will considerably improve your customer alignment and your ability to respond to alters in their demand.
Pull based on Customer Demand
With better flow it is much easier to schedule the manufacturing procedure such that product is pulled v the process based on client demand. Frequently this requires manufacturing in smaller production runs the are directly tied to customer orders.
Pulling manufacturing through the value stream renders it much less complicated to reduce finished product inventory. This is necessary because large finished product inventories and large amounts of WIP (work-in-process) are reservoirs that waste.
It is also important come differentiate in between inventory the you:Need to safeguard your manufacturing procedure from external supply shocks (necessary waste)Don’t need to protect your manufacturing procedure as it is internally developed (unnecessary waste)
As recent background has shown, the real human being is very messy, and also there deserve to be far-ranging unanticipated it is provided chain shocks. One takeaway is the prestige of building and also maintaining productive and positive irreversible relationships v suppliers, so they room willing to hear to your pertains to and aid where castle can.
Strive because that Perfection
Improvement is a journey - not a destination. The five lean ethics are one iterative procedure that will bring further value as they are repeated. Continue to use these values to your manufacturing procedure based on what you learn about your customers, ideal practices because that manufacturing, and also the qualities of her process.
Your overarching goal must be to produce a culture of constant improvement. When it truly becomes your company’s culture, it additionally becomes self-sustaining. Consider achieving this as a key responsibility and natural result of reliable leadership.
SEVEN fatal WASTES
Let’s talk a bit an ext about waste. Traditional lean identify seven key areas of rubbish – generally referred to as the seven Deadly Wastes. These are defined below together with suggested countermeasures. Don’t concern if the countermeasures space not immediately “actionable” for you – right currently they deserve to be thought about simply together a roadmap for the future.
OverproductionWhat is Overproduction?
Making something before it is truly needed. This is a an especially serious kind of waste since it leader to overabundance inventory that is regularly used to mask various other underlying problems and also inefficiencies.What are Countermeasures because that Overproduction?Use a pull system to regulate how much is manufactured (Kanban).
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WaitingWhat is Waiting?Time once work-in-process is waiting for the next step in production (no worth is gift added). It deserve to be important illuminating to look at the time from order come shipment and ask – exactly how much of the time is actually invested on true value-added manufacturing.What space Countermeasures because that Waiting?Design procedures so that the circulation is constant and there space minimal (or no) buffers between steps in production (Continuous Flow).
TransportWhat is Transport?
Unnecessary motion of life materials, work-in-process or finished goods.What are Countermeasures for Transport?Design a linear, sequential flow from raw materials to finished products (Value stream Mapping).Make certain work-in-process is not put into perform (Continuous Flow).
MotionWhat is Motion?
Unnecessary motion of people (movement the does not add value).What room Countermeasures because that Motion?Consider alternating arrangements of tools that reduce motion (Value stream Mapping).
OverprocessingWhat is Overprocessing?
More handling than is needed to develop what the customer requires. This is regularly one that the more an overwhelming wastes to detect and eliminate.What are Countermeasures because that Overprocessing?
InventoryWhat is Inventory?
Product (raw materials, work-in-process, or finished goods) amounts that go beyond supporting the instant need.What space Countermeasures for Inventory?Bring raw materials in only as castle are essential (Just-In-Time).Reduce or remove buffers between steps in production (Continuous Flow).
DefectsWhat are Defects?
Production the is scrap or requires rework.What room Countermeasures for Defects?Design processes so castle are much less likely to create defects (Poka-Yoke).Design processes to detect abnormalities so they deserve to be immediately corrected (Jidoka).Look because that the single most regular defect and determine why it wake up (Root reason Analysis).
Lean concepts end up being a lot an ext intuitive and also easy-to-understand when they are traced to the ultimate score – eliminating waste.
AN EIGHTH fatal WASTE
An incredibly important form of waste that is not represented within the seven Deadly Wastes is unused human potential. This type of waste results in all sorts the lost opportunities (e.g., shed motivation, shed creativity, and lost ideas).
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One that the factors that this indigenous of waste is regularly underemphasized or even ignored at companies is that duty for it lies squarely ~ above the shoulders of management. Unused human being potential regularly results from administration policies and management formats that diminish employee contributions. By way of contrast, developing strong coaching skills for managers have the right to be really effective in increase employee contributions.