"The main objective of lean manufacturing is to reduce times within the production system as well as response times from suppliers and to customers."
A systematic approach to optimize manufacturing processes and eliminate waste.
Value Stream Mapping (VSM): A graphical representation of the flow of materials and information through a manufacturing process, used to identify opportunities for improvement, waste reduction, and process optimization.
Continuous Improvement (CI): A philosophy of continuously seeking to improve processes and products, with the goal of increasing efficiency, reducing waste, and achieving better results.
Single-piece Flow: An approach to manufacturing that emphasizes producing one piece at a time, in a continuous flow, rather than in batches.
Just-in-Time (JIT) Production: An inventory system that emphasizes producing and delivering products on a just-in-time basis, in response to customer demand.
Kanban: A signal used in production to indicate when new materials or products are needed, helping to manage inventory levels and ensure timely production.
Poka-Yoke: A Japanese term meaning "mistake-proofing," used to describe techniques and systems that prevent errors or mistakes from occurring in manufacturing processes.
Lean Six Sigma (LSS): A methodology that combines the principles of Lean Manufacturing with statistical quality control techniques of Six Sigma to achieve process improvement and waste reduction.
Total Productive Maintenance (TPM): A system of process improvement that emphasizes the continuous monitoring and maintenance of machinery and equipment, with the goal of increasing uptime, reducing downtime, and optimizing overall equipment effectiveness.
Standardized Work: A set of procedures and guidelines for performing tasks in a consistent, reliable manner, with the goal of reducing variability and improving efficiency.
5S: A workplace organization and housekeeping system that stands for Sort, Set in Order, Shine, Standardize, and Sustain. It involves creating a clean, organized, and efficient work environment.
Kaizen: A Japanese term meaning "continuous improvement," used to describe a culture of constant improvement and innovation in manufacturing processes and products.
Value Analysis/Value Engineering (VA/VE): A systematic approach to analyzing and improving the value of products and processes, with the goal of reducing costs while improving functionality and quality.
Andon: A visual control used to signal problems or interruptions in production, helping to identify and address issues in real-time.
Gemba: A Japanese term meaning "the real place," used to describe the physical work environment where manufacturing processes take place, and where improvement opportunities are identified and addressed.
Heijunka: A method of production scheduling that seeks to level out the production workload, maintaining a steady pace of production that meets the demands of customers while minimizing waste and variability.
Flow Manufacturing: A manufacturing process that emphasizes continuous material flow, standardization, and automation, with the goal of reducing lead times, cycle times, and variability.
Total Quality Management (TQM): A management philosophy that emphasizes continuous improvement and customer satisfaction, with the goal of delivering high-quality products and services.
Pull Systems: A production system that utilizes demand signals to pull materials and products through the manufacturing process in response to customer demand, rather than relying on a push system that produces products based on forecasted demand.
Theory of Constraints (TOC): A methodology that seeks to identify and remove bottlenecks and other constraints in manufacturing processes, with the goal of improving throughput and increasing efficiency.
Visual Management: A system of visual cues and signals used to monitor and communicate the status of manufacturing processes, helping to identify issues and improve efficiency.
Kaizen: This is a continuous improvement process that aims to optimize and streamline all aspects of production.
Kanban: This type of manufacturing process involves “just in time” production, where materials are ordered and delivered to the assembly line as they’re needed.
5S: This process stands for Sort, Set in Order, Shine, Standardize, and Sustain. It's a structured approach to organizing your workspace for maximum efficiency.
Total Productive Maintenance (TPM): This process focuses on maintaining and improving the efficiency of equipment and machinery to reduce downtime and increase productivity.
Value Stream Mapping: This is a visual tool used to analyze and streamline the flow of materials and information through the manufacturing process.
Single-Minute Exchange of Die (SMED): This process aims to minimize the time it takes to change between manufacturing tasks, such as switching out tools or reconfiguring machines.
Just-in-Time (JIT): This is another process that focuses on delivering materials and products on a “just in time” basis, with minimal waste and inventory.
Continuous Flow Manufacturing (CFM): This process is all about maximizing the efficiency of the assembly line, with a focus on reducing downtime and streamlining the production process.
Andon: This is a real-time notification system that alerts workers to any problems or issues with the manufacturing process, allowing them to quickly respond and resolve the issue.
Lean Six Sigma: This is a combination of the Lean Manufacturing and Six Sigma process improvement methodologies, which work together to optimize and streamline the manufacturing process while minimizing waste and defects.
"Lean manufacturing adopts the just-in-time approach and additionally focuses on reducing cycle, flow and throughput times by further eliminating activities which do not add any value for the customer."
"Lean manufacturing also involves people who work outside of the manufacturing process, such as in marketing and customer service."
"Lean manufacturing is particularly related to the operational model implemented in the post-war 1950s and 1960s by the Japanese automobile company Toyota called Toyota Production System (TPS)."
"Toyota's system was erected on the two pillars of just-in-time inventory management and automated quality control."
"The seven 'wastes' (muda in Japanese), first formulated by Toyota engineer Shigeo Shingo, are the waste of superfluous inventory of raw material and finished goods, the waste of overproduction, the waste of over-processing, the waste of transportation, the waste of excess motion, the waste of waiting, and the waste of making defective products."
"The term Lean was coined in 1988 by American businessman John Krafcik in his article 'Triumph of the Lean Production System'."
"The five key principles of lean manufacturing, as defined by American researchers James Womack and Daniel Jones, are to precisely specify value by specific product, identify the value stream for each product, make value flow without interruptions, let customer pull value from the producer, and pursue perfection."
"By receiving goods only as they need them for the production process, it reduces inventory costs and wastage, and increases productivity and profit."
"The downside is that it requires producers to forecast demand accurately as the benefits can be nullified by minor delays in the supply chain. It may also impact negatively on workers due to added stress and inflexible conditions."
"A successful operation depends on a company having regular outputs, high-quality processes, and reliable suppliers."