Making the lean manufacturing process work for you

The lean manufacturing process is an ongoing work, with no end possible. This is one reason why it is not so easy to "define", much less attain. Because it it a process, you are always striving to improve.

Once you have made a commitment to begin your formal journey, you must decide if you are able to implement such an ongoing process by using your in-house personnel, or if you should hire one of the many lean manufacturing consultants.

One way to begin is to ask other people in a similar industry and size company. You can learn a great deal from the experience of others. Word of mouth recommendations are always the best as well.

What are some lean manufacturing techniques?

Identify the seven areas where waste occurs.

1. Defects
2. Inventory
3. Processing
4. Waiting
5. Motion
6. Transport
7. Overproduction

Some of the processes you will use are:

• 5S Implementation
• Kaizen and continuous improvement
• Value Stream Mapping
• Define Six Sigma

How to use the lean manufacturing techniques to eliminate waste

1. Quality-mistake proofing
2. Flow production-pull systems
3. One piece flow-intelligent automation
4. Lead time reduction 
5. Level loading-mixed model production

Common sense prevails

If you ask a manufacturer who has successfully implemented lean manufacturing techniques, you will find that they truly like it because it is just common sense. The big differerence is that it is monitored and sustained company wide, or at least within a work area or department.

Once a system is in place, it is rather like another spoke on a wheel, making it stronger and better.

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

What about lean manufacturing consultants?

Once you get into the lean manufacturing process, you quickly discover that you are in over your head and need help. It is bit like a 'do it yourself project' at home that you realize is out of your skill set! There are a lot of ways to work with a consultant as well. You can turn it over to them entirely, or work as a team, involving your own people as well.

It is obviously better to include you own people for any number of logical reasons. Nobody likes being imposed upon by some unknown outside interest who really doesn't understand the nitty-gritty of everyday work in your company. On the other hand, a good consultant will make your job much easier so you can do what you do best and leave the rest!

What are the main benefits of the lean manufacturing process?

• Improved morale in your workforce. Once your workers experience the improved conditions, cleaner environment, reduced waste of time and material, and personal ownership of their area, they will be happier and therefore more productive. The days of heavy-handed, mean-spirited 'leadership' are quickly disappearing.
• More profits from higher productivity and less waste.
• Company cohesiveness. When everyone is 'on the same page' and feels a part of the whole, the entire organization is better off. There is more of a team spirit than a owner-worker split.