Lean manufacturing principle-step by step principle

Good Morning Friends,

 Lean manufacturing principles-Implementation

There are several key lean manufacturing principles that need to be understood in order to implement lean. Failure to understand and apply these principles will most likely result in failure or a lack of commitment from everyone in your organization. Without commitment the process becomes ineffective. This page reviews some of the more critical lean manufacturing principles and should help you get started. Consider these to be the "guiding principles" of lean manufacturing as there are others that have not been included.

The five-step thought process for guiding the implementation of lean techniques is easy to remember, but not always easy to achieve:

1. Specify value from the standpoint of the end customer by product family.
2. Identify all the steps in the value stream for each product family, eliminating whenever possible those steps that do not create value.
3. Make the value-creating steps occur in tight sequence so the product will flow smoothly toward the customer.
4. As flow is introduced, let customers pull value from the next upstream activity.
5. As value is specified, value streams are identified, wasted steps are removed, and flow and pull are introduced, begin the process again and continue it until a state of perfection is reached in which perfect value is created with no waste.

 Lean Manufacturing Principles-

Elimination of Waste

One of the most critical principles of lean manufacturing is the elimination of waste (known as muda in the Toyota Production System).

The Seven Wastes of Lean Manufacturing are;

• Transport
• Inventory
• Motion
• Waiting
• Over-Processing
• Overproduction
• Defects

Although the above mentioned types of waste were originally geared toward manufacturing, they can be applied to many different types of business. The idea of waste elimination is to review all areas in your organization, determine where the non-value added work is and reduce or eliminate it.

Kaizen (Continuous Improvement)

Kaizen is the strategy where employees work together proactively to achieve regular, incremental improvements in the manufacturing process.

It should truly form the basis of your lean implementation. Without continuous improvement your progress will cease. As the name implies, Continuous Improvement promotes constant, necessary change toward achievement of a desired state. The changes can be big or small but must lend itself toward improvement (often many small changes are required to achieve the target). The process truly is continual as there is always room for improvement.

Continuous Improvement should be a mind-set throughout your whole organization. Do not get caught up in only trying to find the big ideas. Small ideas will often times lead to big improvements.

Respect For Humanity

The next lean manufacturing principle has to do with people. The most valuable resource to any company are the people who work for it. Without these people the business does not succeed. When people do not feel respected, they tend to lose respect for the company. This can become a major problem when you are trying to implement lean.
Most people want to perform well in their jobs. Not only do they go to work to earn a living, but they also want to develop a sense of worth in their work. They want to feel like they have contributed to the company goals, like their work and effort has meant something.
Some of the methods to ensure your people know you respect them is through constant communication, praise of a job well done, listening to their ideas and helping out when necessary.

Heijunka (Levelized Production)

Heijunka is a form of production scheduling that purposely manufactures in much smaller batches by sequencing (mixing) product variants within the same process
As mentioned on the home page, the foundation of lean manufacturing is levelized production. The basis of this principle is that the work load is the same (or level) every day. Most manufacturing companies are at the mercy of their customers for orders. Before producing product, they wait to get orders. This leads to increased delivery lead time which may not satisfy customer requirements.

On the other end of the spectrum, some companies will produce based strictly on a forecast. This may result in excess product that is not required by the customer. it takes into consideration both forecast and history. The key ingredient for this lean manufacturing principle is utilization of a pull system.

 

Just in time

Pull parts through production based on customer demand instead of pushing parts through production based on projected demand. Relies on many lean tools, such as continuous flow, Heijunka, Kanban, Standardize work and Takt time   Working in conjuction with levelized production, this principle works well with kanbans (a pull system). It allows for movement and production of parts only when required. This means components are not used in product that is not required and no time is wasted building unsaleable product.

Just in time helps to maintain inventory level, also due to just in time concept material & money will not stuck, money flow will be fast. also product  quality will increased so customer satisfaction level will increased.

Quality Built In

The last key lean manufacturing principle that I would like to touch on is Quality in built. The idea behind this principle is that quality is built into the manufacturing process. Quality is built into the design of the part. Quality is built into the packaging. Throughout all areas of the product, from design to shipping, quality is a major consideration.
Automation with a human touch falls within this principle. Machines that can detect defects and stop production are an excellent example of this principle. Part profile mistake-proofing, which prevents an operator from mis-orienting parts, is another excellent example. In Lean Manufacturing (or any other system), the focus must be on doing it right the first time.

 

There are some more principle also involve, you get from basic lean manufacturing concept blog. I am happy after looking the there is someone interested to learn the lean manufacturing. this will not direct helpful to implement the lean manufacturing but helpful to understand the fundamental of the lean.

Thanks friends for reading, in the next blog we can see how to implement the lean manufacturing concept in factory.

Thanks and have a nice day!