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Lean Manufacturing
What is Lean Manufacturing?
Lean manufacturing is a systematic approach to eliminating wastes in the production process. Wastes can be anything that does not add value to a finished product, including processes, materials, and people (i.e., not using employees to their full potential). Lean manufacturing is a continuous improvement process with the end objective of delivering products in the quickest, most efficient, and cost effective manner.
Lean principles are based on the Toyota Production System (TPS) developed in the 1940s. TPS demonstrated that even though processes differ between factories, common wastes and inefficiencies could be found in all types of production environments. TPS was groundbreaking and turned Toyota into a global brand. Over the years, TPS principles have been applied to a number of other non-manufacturing industries such as information services and health care delivery.
As an extension of TPS principles, lean manufacturing focuses on identifying seven forms of wastes:
- 1. Waiting
Waste occurs whenever materials are not moving through a process. - 2. Overproduction
Waste occurs in "Just in Case" operations in which goods are produced in anticipation of possible demand, which can result in excessive lead times, high storage costs and more defects. -
3. Over Processing
Waste occurs when using equipment in processes where cheaper, less complex tools can be more efficient. This activity is commonly referred to as "using a sledgehammer to crack a nut." -
4. Work in Progress
Excessive inventory is a result of overproduction and waiting, and results in longer lead times and higher storage costs. -
5. Transportation
It is wasteful to transport a product between processes. Production should be a smooth flow between one process and another. -
6. Motion
Unnecessary ergonomic activities such as walking, bending, searching, and reaching can add up to delays and longer lead times. -
7. Defects
Defects resulting in re-work and scrap that negatively impacts the bottom line.
These wastes are often symptoms to deeper problems. Companies that fail at lean manufacturing often treat the symptoms rather than taking further steps to identify and resolve root causes, which are often “invisible” on the surface.
In a true lean environment,
- Production is "just in time" – created as needed
- Materials flow through a smooth process in which unnecessary waiting and transporting are eliminated
- Equipment is right-sized to specific production tasks and processes
- Inventory levels are reduced
- Quality and accuracy are improved, and defects minimized
Lean manufacturing leads to higher profits, cost-efficient production, improved quality, greater throughput, improved employee morale and increased time to market.
How Do I Become Lean?
Contact your local Manufacturing Extension Partnership (MEP) Office. MEP offers free and low-cost workshops and hands-on assistance to help small manufacturers learn lean tools, methodologies and practices.
The Lean Manufacturing Online Tutorial provides a step by step explanation of lean principles and how to apply them to your operations. This free course includes videos from lean production expert, James P. Womack, Ph.D.
Case Studies & Success Stories
Check out these case studies to learn how organizations have successfully implemented lean principles:
- Lean Management Success Stories
From the New Jersey Manufacturing Extension Partnership. - Lean Manufacturing and the Environment – Case Studies & Best Practices
Discover how lean concepts and tools results in improvements in environmental performance, even when lean activities were not initiated for environmental reasons. - Manufacturing Extension Partnership Success Stories
Read summaries of how manufacturers have become lean and profitable by taking advantage of MEP programs and services. - Success Stories in Health Care Delivery
Read cases studies on how lean manufacturing principles have been applied to hospitals and health care centers.
References
Government agencies, non-profits and educational institutions have a number of programs and services to help you learn about lean manufacturing.
Best Practices Resources
- American Society for Quality’s Lean Enterprise Division
Offers training and resources in lean principles and practices that can be applied across the enterprise. - EPA - Lean Manufacturing and the Environment
Tools and resources to help manufacturers adopt lean practices that protect the environment. - Green Suppliers Network
This partnership between EPA and the Manufacturing Extension Partnership works with manufacturers to engage small and medium-sized suppliers in low-cost technical reviews that focus on process improvement and waste minimization. - Lean Enterprise Institute
A non-profit corporation founded by James P. Womack, Ph.D to promote a set of ideas commonly known as "lean thinking." - Northwest Lean Networks
Assists companies implement lean manufacturing and lean production systems.
Lean Tools & Methods
Lean manufacturing is a continuous process rather than a destination. Becoming lean means creating a performance-based, customer-centric company in which all employees are engaged in lean initiatives. Getting there requires the adoption of tools and methods to help you eliminate wastes and their root causes, and become more efficient and profitable. The following resources provide starting points for learning about lean tools:
- Lean Thinking and Methods
EPA has compiled a list of common methods for implementing lean manufacturing practices. - Lean Enterprise Best Practices Mini-Assessment
Find out how your company compares to leading lean manufacturers. - EPA Lean and Environment Toolkit
Offers practical techniques and strategies for developing environmentally protective lean decisions as a routine task of your lean-driven business operations.
Sector Initiatives
- Lean Aerospace Initiative
The Lean Aerospace Initiative (LAI) at the Massachusetts Institute of Technology helps focus understanding and application of lean techniques in the aerospace sector. - Lean Construction Institute
Reform the management of production in design, engineering and construction for capital facilities. - Lean Shipbuilding Initiative
A national initiative to make the shipbuilding industry competitive by applying lean manufacturing principles. - Society of Automotive Engineers
Suite of products and services designed to assist the automotive and aerospace industries in the development, implementation, documentation, and dissemination of lean enterprise principles and practices. - United States Army Lean Six Sigma Program
The United States Army has began an effort through Army Materiel Command to reduce waste throughout every process.
