Reading this section you will explore many definitions on What is Lean Manufacturing.
I will reveal my favourite but you can choose the definition you like the most.
Let's start with an image.
This image summarizes that Lean Production is not about the COST REDUCTION.
Lean Production is to increase
- Quality
- Speed
- Results
with the consequence of cost reduction.
So the first step is to not believe in Lean Projects where the main scope is the cost reduction.
Another real important point is to understand that.
Lean Principles can be applied to every field of industry and life.
To give you an example I propose you this 6 minutes video.
- Lean is not a cost reduction project.
- Lean can be applied in every field ... no excuses.
The most authoritative Lean Definition ... from the present.
There are many Lean Centre and Lean Institutes that are constantly studying Lean Definitions.
I would like to reveal you which is, in my opinion, the best ...
The winner is ... Lean Enterprise Institute.
From their web site you can really find a lot of material to understand Lean Concepts.
Now I will report and comment their definition on what is lean manufacturing.
The most authoritative Lean Definition ... from the past.
Just in Time
The first pillar of Lean.
Jidoka (Autonomation)
The second pillar of Lean.
- The Lean Startup method ask to measure people's productivity in a different way.
- The objective is to understand the right product to develop.
- The product that customers want and are willing to pay.
Here, a very interesting video that summarize the Lean Startup.
It is time go into Lean benefits details...
5S is part of the Lean Journey is not the only part.
Other Benefits of Lean Manufacturing normally listed are:
Inventory Reduction
Set-Up Time Reduction
Defects Reduction
Efficiency and Productivity
Machine Breakdown Reduction
High Delivery Performance
Customer Satisfaction
Employee Satisfaction
Supplier Satisfaction
Is it possible? All these benefits?
Why all the companies in the world do not use it?
Even if it is not easy to believe it is true.
I can clearly state that I saw with my eyes:
Set-Up from hours to minutes.
30% Inventory Reduction
20% Productivity Increase
I know is hard to believe but it is real.
The other face of the coin is the to obtain these results is a hard work.
You need a deep cultural change and it not happens overnight.
In fact is the Lean Journey, not the Lean week-end.
If you will continue to follow me in this section I will tell you how it is possible to reach unbelievable results in your company.
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Du Pont Production System
A video from ABB show the extraordinary results they got:
Here a video on the Lean Management in GE.
Finally, the results of Philips.
The list is clearly not complete.
When I will put other companies on the list I will you update.
But, to be updated you have to join the community [ scroll up 🙂 ].
The complete definition of what is Lean Manufacturing, from my favorite source.
Here is the kicker!
” A lean organization understands customer value and focuses its key processes to continuously increase it. The ultimate goal is to provide perfect value to the customer through a perfect value creation process that has zero waste.“
My comment:
2 keywords you have to fix in mind:
- Key Processes
- Continuous Improvement
Following these sections, I will give you the best practice to focus on the Key Processes.
About the Continuous Improvement I would like to challenge you.
I think that in your life you had the chance to travel.
You normally put clothes in a suitcase or bag.
Do you think the way you use is the best or there is something that you could improve?
Answer in your mind before the following video ...
YES
NO
Now,
look at the video and be sincere with your answer ...
How to became a Lean Company?
My comment:
To change the focus of the management is probably the hardest part.
In particular the middle management.
It not easy to ask the inventory manager to accept an increase in inventory in the first period of the Lean Implementation even if it is something to accept in the long term strategy.
The two keywords:
- Change the focus of the Management
- From Vertical to Horizontal (the flow)
What increase and what decrease with Lean Management
Eliminating waste along entire value streams, instead of at isolated points, creates processes that need less human effort, less space, less capital, and less time to make products and services at far fewer costs and with much fewer defects, compared with traditional business systems.
Companies are able to respond to changing customer desires with high variety, high quality, low cost, and with very fast throughput times. Also, information management becomes much simpler and more accurate.
The Lean books that really you have to read to understand What is Lean.
Follow these steps for your "Lean Traning":
- Buy and read the book I suggest
- Start with a project in a limited area of the company
- Learn from experience (with solid knowledge by books reading)
- With less than 300 $ you will have valuable experience in Lean.
Toyota Production System: Beyond Large-Scale Production
All these books are my essentials. Just with this book you can start the Lean Journey and follow for 1-2 year. In the following section I will suggest you specific books for a higher level of implementation.
Remeber! The Lean Transformation is a journey not a week-end.
Before the last part.
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Read now our guide on a successful
5S Methodology implementation.
