Lean Manufacturing – Saving Time, Space and Money
Lean Manufacturing
is a manufacturing system and a philosophy originally developed by
Toyota in their Toyota Production System but is now successfully
used throughout the world.
The term "Lean" literally means to cut out the "fat" in the production process that makes it inefficient and doesn't add value to the product. The idea behind the concept is that many manufacturers could work more economically by using their time, production space or other production influencing factors more efficiently. With the easy steps of Lean Manufacturing you can achieve a much more efficient use of your production time, space, machines and tools. You can limit the potential for accidents and injury within you company and assure a high and stable quality level of your products, which will especially satisfy your customers. Additionally you will create a more attractive work place for your employees.
The term "Lean" literally means to cut out the "fat" in the production process that makes it inefficient and doesn't add value to the product. The idea behind the concept is that many manufacturers could work more economically by using their time, production space or other production influencing factors more efficiently. With the easy steps of Lean Manufacturing you can achieve a much more efficient use of your production time, space, machines and tools. You can limit the potential for accidents and injury within you company and assure a high and stable quality level of your products, which will especially satisfy your customers. Additionally you will create a more attractive work place for your employees.
A manufacturing company from Oklahoma City, OK, reported on a 30%
saving of space and an improvement in production of 10-15% after
implementing Lean Manufacturing in their plant.
How can you implement Lean Manufacturing in your company?
First of all it is important that you apply the following three principles:
It is worth noting that Lean Manufacturing affects everything related to the production process, including people, processes and technology!
To start Lean Manufacturing in your company with a minimal investment, you can begin with 5S, the foundation of a lean environment. 5S is the name of a workplace organization methodology that uses a list of five Japanese words which, transliterated and translated into English, start with the letter S.
5S stands for:
This sounds easy and it really is! Once you walk through your facility you will notice how much time and space you'll be able to save if you apply 5S consistently.
Another tool identifies all factors in your production that do not add value to your production. According to Shigeo Shingo, inventor of the Toyota Production System, these factors are considered waste and must be eliminated. He identified seven forms of waste.
7 Forms of Waste:
The total elimination of waste inventory would create Just-in-Time Production which is, of course, not suitable for every business. However, it might be suitable for those companies wishing to reduce their inventory and to review their order system closely. Download the worksheet here to use to help you record your observations.
If you have questions, give us a call at 888-472-9655, prompt 1, ext. 6964 or email consulting.us@heidelberg.com
How can you implement Lean Manufacturing in your company?
First of all it is important that you apply the following three principles:
• The pursuit of continuous improvement
• Focus on total quality
• Keep cycles short
It is worth noting that Lean Manufacturing affects everything related to the production process, including people, processes and technology!
To start Lean Manufacturing in your company with a minimal investment, you can begin with 5S, the foundation of a lean environment. 5S is the name of a workplace organization methodology that uses a list of five Japanese words which, transliterated and translated into English, start with the letter S.
5S stands for:
• Sort - clean up and organize your work area
• Set In Order - identify and arrange everything you need in the work area
• Shine - assure regular cleaning and maintenance
• Standardize - make it easy to maintain - simplify and standardize
• Sustain - maintain what you have accomplished
This sounds easy and it really is! Once you walk through your facility you will notice how much time and space you'll be able to save if you apply 5S consistently.
Another tool identifies all factors in your production that do not add value to your production. According to Shigeo Shingo, inventor of the Toyota Production System, these factors are considered waste and must be eliminated. He identified seven forms of waste.
7 Forms of Waste:
• Transportation • Over Production • Inventory • Over Processing • Motion • Defects • Waiting
The total elimination of waste inventory would create Just-in-Time Production which is, of course, not suitable for every business. However, it might be suitable for those companies wishing to reduce their inventory and to review their order system closely. Download the worksheet here to use to help you record your observations.
If you have questions, give us a call at 888-472-9655, prompt 1, ext. 6964 or email consulting.us@heidelberg.com
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