What is lean manufacturing?

How to effectively manage production to reduce losses while increasing efficiency? The answer to this question may be lean manufacturing – a management method focused on eliminating losses, developed in the 20th century based on the production systems used by the Toyota brand. An approach based on several important foundations has allowed for the improvement of quality along with the reduction of production costs, gaining recognition in numerous companies and industries. What is worth knowing about this topic? It is certainly worth noting that modern companies use a number of systems supporting work in production, starting with the MES, SCADA, or CMMS systems . The latter are widely used 

The most important assumptions of lean manufacturing

The beginnings of lean manufacturing date back to the 1950s , the post-war period, which was associated with economic difficulties for many countries. Economic problems also affected Japan, where this method was created – it is based on the same assumptions as the Toyota Production System (TPS). TPS, in turn, includes certain key aspects that later became the basis for the lean concept:

• JIT (just-in-time) – delivering required production elements exactly when they are needed;
• jidōka – automation of work and devices performed with human participation in order to maintain full control over production processes;
• kaizen (lit. “improvement”) – continuous improvement and striving to optimize all stages of the process.

Based on the above pillars, the concept of lean management assumes that instead of producing to stock, it is worth adjusting production to current market demand . This approach allows to avoid wasting resources and also shorten the order fulfillment time. Lean management is usually described as a set of five main principles:

• Defining value – identifying and understanding what is most important from the customer’s perspective.

• Value stream mapping – identification of individual stages of the production process, with an emphasis on locating places where losses occur.

• Creating continuous flow – striving to maintain production flow without downtime or delays.

• Operating according to the pull system – carrying out production based on real demand instead of sales forecasts.

• Continuous improvement – ​​ongoing improvement of processes and elimination of losses.

Lean management in the manufacturing industry

Lean management is an approach that places particular emphasis on the optimization of activities at the management level . In the manufacturing industry, this means that managers are responsible for ensuring the efficiency and consistency of production processes. Depending on the characteristics of the company, such activities can take different forms – however, lean implementation should always include building employee engagement, staff training and monitoring results in order to achieve the best possible results without unnecessary expenditure. It is essential to nurture the organizational culture of the company and constantly support kaizen initiatives. In addition to employee development, one cannot ignore aspects strictly related to production – we are talking about regular reviews of processes and introducing innovative improvements, which may include, for example, IoT solutions (Internet of Things).

Lean Manufacturing Waste Elimination and Lean Tools

The central element of lean management is the elimination of losses , called the Japanese term “muda” (literally “waste”). In production, there are seven types of losses that must be eliminated to achieve the greatest possible process optimization:

• overproduction – producing more than is needed
• waiting – downtime resulting from waiting for materials, tools, or decisions;
• excess inventory – accumulation of materials and semi-finished products that are not needed at the current stage of production
• unnecessary transport – moving materials without added value
• processing – doing more than required
• unnecessary movements – suboptimal actions of employees or machines
• manufacturing defects – manufacturing parts or items that are defective or require improvement.

How to get rid of the above losses? To do this, you can use certain tools that help identify and eliminate waste, which are examples of lean manufacturing implementation. Among the most popular is 5S, a method of organizing the workplace focused on improving efficiency and safety . This term covers five steps, each of which begins with the letter S: sorting (removing everything that is not needed from the workstation), systematics (clearly marking tools and materials, placing them in visible, established places), cleaning (organizing the workstation), standardization (defining standards for the arrangement of tools at the workstation) and self-discipline (developing the habit of following other rules). In addition, companies use, among others, the kanban task and material flow visualization system , which allows for a clear presentation of project progress. It is also worth paying attention to the poka-yoke method of preventing errors , as well as the JIT (Just-In-Time) material delivery system , which eliminates the need for storage.

Benefits of Lean Management in Manufacturing

Lean management, based on relatively simple assumptions, is a concept that is well-respected in many manufacturing companies around the world, and for good reason. The main reason for the popularity of lean management is the numerous benefits that affect both operational efficiency and customer satisfaction . Manufacturing companies that focus on lean manufacturing can count primarily on reducing production costs by eliminating losses, which is also associated with improving quality due to the elimination of defects and errors in processes. The use of JIT, on the other hand, allows for shortening the order fulfillment time. Due to the fact that lean management also involves building employee engagement, increased staff satisfaction can also be achieved. Another important advantage is better flexibility – lean allows for quick response to potential changes in customer demand.

Lean manufacturing is becoming increasingly important now, in the era of Industry 4.0 and modern technological solutions in production. By combining with concepts such as IoT, lean management can be even more innovative and effective. As a result, it is a key strategy for companies striving for lasting success , which can be seen in the example of Toyota, the creator of this solution, as well as many other companies from virtually every sector.

Summary

Lean manufacturing, a methodology derived from the Toyota Production System, offers a structured approach to optimizing production processes and eliminating waste. Focusing on fundamental principles such as just-in-time production, automation, and continuous improvement, lean manufacturing has revolutionized the way companies operate.