Lean Manufacturing

What is Lean Manufacturing #

Lean manufacturing is a production philosophy that aims to eliminate waste and create value for the customer by maximizing efficiency and minimizing non-value-added activities. Lean manufacturing is based on the idea of continuously identifying and eliminating waste in all aspects of the production process, in order to create a more efficient and streamlined operation.

The goal of lean manufacturing is to deliver the right product, to the right customer, at the right time, in the right quantity, and at the right cost. This is achieved by focusing on the flow of value through the production process, and eliminating any activities that do not directly add value to the product or service being produced.

To implement lean manufacturing, companies often use tools such as value stream mapping, just-in-time production, one-piece flow, standard work, and visual management, among others. Lean manufacturing can be applied to a variety of industries, including manufacturing, healthcare, and service sectors.

Common Lean Manufacturing Terms #

Andon #

Andon is a lean manufacturing tool that is used to alert the appropriate personnel when a problem or issue occurs in the production process. The term “andon” comes from the Japanese word “andon,” which means “lamp” or “light.” In a lean manufacturing environment, an andon system is often used to visually communicate problems or issues to the appropriate personnel.

Gemba #

Gemba is a term used in lean manufacturing and refers to the place where value is added or where work is actually done. It is often used in the context of “going to gemba,” which means physically visiting the place where work is done in order to observe and understand the process and identify opportunities for improvement.

Heijunka #

Heijunka is a term used in lean manufacturing and refers to the practice of leveling or smoothing out production so that it is more consistent and predictable. It is often used to reduce variability and waste in the production process and to improve efficiency.

Just-In-Time Manufacturing (JIT) #

Just-in-time (JIT) manufacturing is a production strategy that involves producing and delivering products just in time to meet customer demand, rather than producing and storing large quantities of inventory. JIT manufacturing aims to minimize inventory levels and reduce waste by producing products only when they are needed and in the quantities required.

Kaizen #

A Japanese term meaning “continuous improvement,” often used in the context of lean manufacturing to refer to a culture of continuous improvement.

Kanban #

A visual signal or card that triggers the production or movement of goods.
Just-in-time (JIT) production: A lean manufacturing approach that aims to produce only what is needed, when it is needed, in the amount needed.

Kata #

Kata is a term used to describe a structured, repetitive practice routine used in martial arts and other physical disciplines. The purpose of kata is to improve technique, build muscle memory, and develop a deeper understanding of the principles and movements of the discipline. Kata is often performed alone or with a partner, and can involve various techniques such as strikes, kicks, blocks, throws, and holds.

In recent years, the term “kata” has also been used in the business world to refer to a structured, repetitive practice routine for developing skills and improving processes. In this context, a kata is a series of steps or a set of best practices that are followed in a consistent, repeatable way to achieve a specific goal or objective. The goal of business kata is to promote continuous improvement and build problem-solving skills in individuals and teams.

Lead Time #

The time it takes to complete a process, from start to finish.

Near-Miss #

A Safety near-miss is an unplanned event that could have resulted in an injury to a team member. For example, a piece of equipment could have malfunctioned, or a worker could have made a mistake that almost injured someone. Near misses are often investigated to identify the root cause and take steps to prevent similar incidents from happening in the future.

One-Piece Flow #

A lean manufacturing technique that involves producing one unit at a time, rather than producing in batches.
Takt time: The rate at which a product must be produced in order to meet customer demand.
Value stream mapping: A lean tool used to identify and eliminate waste in the production process.

PDCA (Plan-Do-Check-Act) #

PDCA is a systematic approach to continuous improvement that was first developed by Dr. W. Edwards Deming, a statistician and pioneer in the field of quality management. It is also known as the Deming Cycle or the Shewhart Cycle.

Poke Yoko #

Poke yoke is a lean manufacturing tool that is used to prevent errors or mistakes from occurring in the production process. The term “poke yoke” comes from the Japanese words “poku” (meaning “mistake-proofing”) and “yokeru” (meaning “to avoid”).

Production Efficiency #

Production efficiency refers to the effectiveness with which a company converts inputs (such as labor, raw materials, and energy) into outputs (such as finished goods or services). It is a measure of how well a company is using its resources to produce the desired results.

Pull System #

A pull system is a type of production system that is based on customer demand rather than forecasting. In a pull system, production is triggered by actual customer orders, rather than being planned in advance based on predicted demand.

Single minute exchange of dies (SMED) #

A lean tool used to reduce the time it takes to change over from one product to another.

Standard Work #

A set of standardized procedures and work instructions for a particular process, used to ensure consistent performance and improve efficiency.

Takt Time #

Takt time is a term used in lean manufacturing and refers to the pace at which a product or service must be produced in order to meet customer demand. It is calculated by dividing the total time available for production by the number of units that need to be produced. For example, if a company has 8 hours of production time per day and needs to produce 100 units per day, the takt time would be 48 seconds per unit (8 hours * 60 minutes/hour / 100 units).

Total preventive maintenance (TPM) #

A maintenance approach that involves all employees in the maintenance and improvement of equipment.

TWI (Training Within Industry) #

TWI is a methodology for training and developing employees that was developed by the U.S. government during World War II as a way to improve productivity and efficiency in the manufacturing sector. The TWI program consists of three core training modules: Job Instruction (JI), Job Methods (JM), and Job Relations (JR).

Value-added activity #

Any activity that directly contributes to the production of a product or service that the customer is willing to pay for.

Value Mapping #

Value mapping is a tool used in business to identify and understand the value that a company delivers to its customers. It is a visual representation of the steps and activities involved in creating and delivering a product or service, and it helps to identify the key value drivers and sources of value for the business.

Visual Management: #

A lean tool that uses visual indicators to communicate information about the production process, such as progress, status, and problems.

Waste #

Any activity that consumes resources but does not add value to the product or service being produced.

5S #

A lean tool used to improve organization and cleanliness in the workplace, consisting of the following five steps: sort, set in order, shine, standardize, and sustain.