Lean Manufacturing Guide

The high level of waste in the manufacturing process has led to a gap between actual profits and company expectations. According to Forbes, as much as 20% of every dollar invested in the industry is wasted, amounting to $8 trillion, or 10% of the Gross World Product (GWP).

This guide will provide a deeper understanding of lean manufacturing and its supporting methods that can help reduce waste in the manufacturing process.

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Chapter 1: Lean Manufacturing: Definition & 3 Benefits

June 26, 2023

Lean manufacturing is a production process that aims to eliminate waste (muda, mura, muri) and increase company profitability. Implementing lean manufacturing is an effective strategy for cutting waste and boosting company profits. The House of Lean Production provides a straightforward approach to comprehending the practical application of lean manufacturing.

Chapter 2.1: 5S Implementation Strategies in Lean Manufacturing

June 26, 2023

Stability is one of the keys to lean manufacturing. Stability starts with the implementation of visual management and a 5S system that supports TPM. 5S is a system that supports visual management and consists of five components: sort, set in order, shine, standardize, and sustain. Each of them has a method to make implementation easier.

Chapter 2.2: Total Productive Maintenance in Lean Manufacturing

July 14, 2023

Stability is one of the foundations of lean manufacturing. Stability is supported by 5S which includes TPM (Total Productive Maintenance). TPM holds the key to production stability by emphasizing proactive and preventive maintenance. Its primary goal is to maximize equipment operational efficiency and eliminate the six significant losses that hinder productivity.

Chapter 3: Standardized Work: 3 Elements, Charts, and its Benefits

July 14, 2023

Standardized work is the safest and most effective way to do work. Companies can boost labor density by increasing value-added work through standardized work. The ultimate aim of standardized work is kaizen. Standardized work identifies muda and involves team members to drive development. It differs from lean production and engineering methods in its approach.

Chapter 4: Just in Time (JIT): Definition & 8 Application Steps

July 14, 2023

Just in Time (JIT) is a strategy to reduce waste in the production process. The goal of implementing JIT is to ensure a continuous production flow, leading to improved company efficiency. JIT has been successfully utilized by renowned companies like Dell and Apple, demonstrating its effectiveness in optimizing the production process.

Chapter 4.1: Kanban: Definition, 6 Rules, and its Benefits

July 17, 2023

Kanban is a method for visualizing work so that it becomes more visible and controllable. It helps companies identify inefficient business processes and find solutions. In practice, there are two commonly used types of Kanban: 1. Production Kanban: This type specifies the type and quantity of products the upstream process produces (suppliers). 2. Withdrawal Kanban: This type determines the type and amount of products downstream processes (customers) can withdraw.

Chapter 4.2: Work-in-Progress (WIP): its Definition and Functionalities

July 18, 2023

Work in Progress (WIP) is half-finished goods waiting to be completed. Work-in-Progress (WIP) is unfinished work that still needs to be completed. It includes costs for things like overhead, labor, and materials. The fewer WIPs there are, the more efficient the company’s production and accounting processes will be.

Chapter 4.3: Understanding Heijunka: Definition and 2 Key Methods

July 18, 2023

Heijunka is the process of distributing production volumes and mixing them evenly over time. It offers two approaches for implementation: leveling by type and leveling by volume. Applying Heijunka can streamline the production process, leading to several benefits.

Chapter 4.4: Pull System: Definition, Its 3 Types & Differences with Push

July 18, 2023

The pull system is part of Lean manufacturing to reduce waste, because it produces when there is a customer order. When implementing the pull system, it’s essential to understand how it differs from the push system. Pull systems generally have three types: A, B, and C, each with advantages.

Chapter 4.5: Value Stream Mapping (VSM): Definition & 4 Mapping Steps

July 21, 2023

Value Stream Mapping (VSM) is a tool to visualize all work steps and help improve work processes. Value Stream Mapping is a tool used to help visualize in detail all steps in the work process from supplier to customer. VSM aims to improve operations by visualizing value-adding and waste steps. In its implementation, VSM is closely related to Kanban.

Chapter 5: Jidoka: Definition and its 2 Implementation Strategies

July 21, 2023

Jidoka is a strategy that can be used to reduce potential product defects at the lowest cost in a short lead time. t plays a crucial role in achieving high-quality results at the lowest cost and in the shortest time possible. We can implement Lean manufacturing production by adopting a long-term jidoka strategy.

Chapter 5.1: Implementing Poka-yoke: Strategies and 3 Detection Methods

July 21, 2023

Poka Yoke is a method used to detect errors and prevent product defects early. It involves two actions: stopping the machine and providing a warning in case of a mistake. Poka-yoke is commonly found in manufacturing companies that heavily rely on devices.

Chapter 6: Employee Involvement: Significance & 3 Supporting Factors

July 28, 2023

Engagement is at the heart of Lean manufacturing. Engagement helps improve employee capabilities and company prospects. Three activities support successful participation in the company: kaizen circle activities, practical kaizen training, and suggestion programs. Involvement is vital in Lean manufacturing, it helps team members develop their skills and increases the chances of long-term success.

Chapter 7: Hoshin Kanri Strategic Planning and Its 5 Support Systems

July 28, 2023

Hoshin Kanri (Hoshin planning) is a part of the House of Lean Production that supports employee involvement in planning. Hoshin Kanri is an integral part of Lean manufacturing that involves everyone in the company working together to create strategic plans. It helps align resources and goals effectively.

Chapter 8: Creating Lean Culture: Strategies & 6 Supporting Methods

July 31, 2023

Lean culture is a culture that is driven by customer focus and involves the role of all workers in the company. Six critical factors support a lean culture: PDCA, standardization, visual management, teamwork, intensity, and paradox.

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