What is lean manufacturing?

The image to the left answers very clearly the question: 'what is lean manufacturing?'

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.

The windmill on the left is efficient and streamlined for maximum output, while the old, nostalgic windmill is quaint, but inefficient. It took a long time and a lot of development to get from the past to the present, and it is the same with a manufacturing company.

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.

What is the lean manufacturing process?

• 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.

5S

• Probably one of the easiest lean manufacturing processes to implement. It gets everyones attention, provides immediate benefits and "makes sense" to almost anyone.
• 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. These mini-Kaizens are like raindrops that add up to make a flood. 

 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.

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, identify areas of waste, you need a way to monitor your progress.

 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.

1. Determine which aspects of lean manufacturing apply to you and prioritize by your needs and abilities.
2. Categorize your people into groups according similar training needs.
3. Identify your programs and make a chart, or matrix.
4. Decide whether you will hire a consultant, or do it in-house
5. Develop a time-frame or schedule according to personnel or work area
6. Prepare an immediate schedule to begin

It is important to make a good beginning, but just as important to follow through immediately. People generally forget what they have learned rather quickly, if they do not make use of it.
 

Where can you find a good resource?

This is an excellent resource used by hundreds of business owners. You can download you own personal copy by clicking here here. It comes with a money back guarantee, and you are certain to find it extremely useful in your search for answers.

You can download it here