Lean is a whole way of thinking. A way of thinking that optimizes the work process. It uses principles of work and tools for this.
The basis of the concept of lean manufacturing is the ruction of losses. Losses are consider to be everything that does not make the product more valuable. To ruce costs, the work process is optimiz as much as possible, simplifi where necessary. Another important detail of Lean is the constant striving for perfection.
Types of losses
Waste and the work to ruce it are a big part of this way of thinking. The creators of lean manufacturing distinguish seven types of waste. They may be call differently in different sources.
- Partially complet work. When work on a telemarketing data product or its component is not fully complet, it is of no use and has no value. This means that resources and time have been wast.
- Extra steps or processes. These are processes that take time and effort, but do not make the product more expensive. Such a process could be, for example, writing reports.
- Unne features or overproduction. A new feature or functionality may be useful, but if the customer doesn’t ne it, it won’t affect the price of the product.
- Multitasking and movement. Each employee, and the team as a whole, works on one task as efficiently as possible. The more tasks are perform simultaneously, the less efficient the work.
- Waiting: Work time wast because the process may have stopp or slow down at other stages.
- Transportation or movement. When workers are far apart, or the assembly/work process itself is spread out, the time for communication or movement of product parts through the production stages increases.
- Defects: Defective products have low value or cause the team to waste time fixing the defects.
Sources of losses
There are also three types or sources of losses.
- Muda is uselessness, excess, wastefulness. how is artificial intelligence changing the recruitment process? These are the losses describ above.
- Mura – unevenness, lack of rhythm. Costs arising from an intermittent schule, uneven production.
- Muri – unreasonableness, overload. Japan Data Excessive workload of employees, which makes them less effective in the long run.
Lean principles
Lean manufacturing contains several principles and a number of values. The values here probably play a greater role, as they reflect and explain the entire concept.
- Elimination of losses.
- Strengthening learning.
- Making decisions at the last crucial moment.
- Rucing delay times.
- Respect for the team and working on its effectiveness.
- Product integrity and quality.
- Seeing the big picture.
The principles are achieving maximum quality and eliminating costs. Five stages of their implementation are distinguish.
- Definition of product values.
- Defining the value stream.
- Ensuring the continuous flow of this stream.
- Allowing the consumer to pull the product.
- Striving for perfection.
Tools
Lean provides a wide range of tools. Some tools regulate equipment readjustment, others organize the workplace, and others analyze labor results. Interestingly, most tools are applicable in various areas of production. Here are some of them.
Value Stream Map
A value stream map is a diagram that shows the movement of a product or specific functionality through stages.
Each stage is highlight in a rectangle and connect with an arrow to the next one. Under the chain of rectangles, the time that the product spent in each of them and spent moving between them is depict. Bas on the time flow map, it is easy to calculate which stages take more time, as well as how many hours or days in total are spent waiting or transitioning.
5 “Why?”
The Five Whys is a problem-solving method that gets to the root of a problem or loss. This is achiev by asking five Whys in succession when a problem is discover. After this, the solution usually becomes much more obvious.
5S
5S is also one of the lean tools aim at improving the organization of the workplace. It consists, as you might guess, of five components or steps (5 Steps).
- Sorting is the division of all items into necessary and unnecessary ones, and getting rid of the latter.
- Keeping things in order means organizing the storage of necessary things in such a way that they can be easily access.
- Keeping the workplace clean – regular cleaning of the workplace.
- Standardization is the creation of standards for the three steps describ above.
- Improvement – maintaining establish standards and improving them.
Application of Lean
Lean manufacturing is most beneficial to implement in manufacturing industries. This is where Lean allows for serious savings and cost ruction. The way of thinking and tools are easy to implement both on an enterprise scale and in small teams. In the software industry, even lean software development has been creat – a methodology that uses the Lean concept and its principles.
The beginning of the widespread use of lean manufacturing technologies was laid by Toyota. Following its example, many large companies during various crises began to look for ways to ruce costs and came to Lean. Now its principles are follow by 2/3 of companies in the USA. Partly also because the state contribut to the dissemination of methods.
In Russia, not many companies want to organize their work process using philosophy. However, large companies are gradually moving to new production methods. Russian Railways, KAMAZ, Irkut and Rosatom have successfully implement Lean and achiev good results thanks to it.
Literature about Lean
There is a lot of literature written about lean manufacturing, as well as about flexible methodologies. Three books that will help you start to understand Lean and apply it.
- “Lean Manufacturing: How to Eliminate Waste and Make Your Company Prosper” by James P. Womack, Daniel Jones.
