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lean manufacturing

Continuous Process Improvement and Eliminating Waste Through Lean Manufacturing

The term “lean manufacturing systems” refers to the most recent manufacturing methods that maximize value while minimizing waste. It is designed to improve any company’s manufacturing line with a strong emphasis on waste reduction or elimination.

When wastes are reduced, the quality of the products or services improves, so do the production time and cost of manufacturing the goods. Keeping this in mind, many businesses invest in lean manufacturing training to get the most out of their systems.

The goal of lean manufacturing for any business is to directly link production and demand. As a result, you can deliver your goods to the customer more efficiently because you produce the product when the customer wants it.

In terms of lean manufacturing systems, value is essentially what the customer is willing to pay for. A company must first determine or survey what its customers truly require, and then devote all of its energies and resources to those valued goods.

Furthermore, in terms of lean manufacturing systems, waste is the inverse of value. Everything that exceeds the value assigned to a specific item is considered waste. Anything for which the customer is unwilling to pay is also considered a waste.

The removal of this waste can be easily manifested in at most eight different categories:

Overproduction

Overproduction in lean manufacturing systems refers to the production of a specific good at a higher level and in greater quantity than is required. When a customer orders a product, the company must manufacture it and deliver it on time.

The issue arises when the company overproduces the goods and the customer only purchases what he requires upon delivery. What is left of the products is then considered waste because its quality has deteriorated and the customer is unwilling to pay for it. If a company has lean manufacturing systems, it can monitor how much it should produce and avoid overproduction.

Inventory

Inventory problems arise when the stock is less than the demand from customers. If a customer is unable to obtain what he desires, the company’s image suffers. Lean manufacturing systems can be implemented to avoid stock depletion due to insufficient inventory. When a stock is nearly depleted, it must be replenished.

Defects

Correcting defects has always been a part of lean manufacturing systems. It aims to reduce defects in the manufacturing line by improving processes and implementing automation at specific points along the production line. Defects are sometimes thought to be the result of human error, but they can also be the result of improper machineries.

Additional Processing

Extra processing, as defined by lean manufacturing systems, refers to processes that appear to be redundant in the system. Lean manufacturing systems can solve extra processing by simply monitoring and identifying which specific processes are no longer required by the manufacturing line. The goal is to eliminate unnecessary processes and improve the manufacturing line.

Waiting Period

According to lean manufacturing systems, waiting time is the unnecessary time spent and wasted along the manufacturing line. Again, whatever processes or loops that lean manufacturing systems can avoid are implemented.

People who are underutilized

People who are underutilized are also a concern for lean manufacturing systems. It seeks appropriate solutions to the problem of underutilized people. Automation processes implemented along manufacturing lines have resulted in a reduction in the need for people.

Motion

Lean manufacturing systems are also concerned with the motion of the manufacturing line. Manufacturing line processes must be streamlined and improved, and lean manufacturing systems have devised solutions to eliminate unnecessary processes.

Transportation

The transportation wastes that a manufacturing company will incur are also a concern for lean manufacturing systems. Lean manufacturing systems have solved some of the issues by centralizing manufacturing operations per plant, allowing each plant to act and manufacture independently.

As we can all agree, the advantages of lean manufacturing systems are numerous, including shorter lead times, greater flexibility, and increased sales.

The internal influence of lean manufacturing systems is to reduce operating space and progress in the work, aside from quality improvements and almost no expenditures.

Additionally, lean manufacturing systems can benefit the company by reducing scrap to approximately 90%, as well as reducing set-up and lead times to approximately 90% and 50%, respectively. Companies that use lean manufacturing systems can achieve about 20 inventory turns per year.

Are You Ready To Drive Waste Out From Manufacturing Process? Download a FREE copy of our Wastes In New Product Development Guide and start to learn on how to eliminate wasteful activities that eats up your company’s time and resources.

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