Lean Manufacturing Principles

Study Notes

A lean manufacturing system is a systematic approach to identifying and eliminating waste in production processes.
Focuses on maximizing value-added activities and minimizing non-value-added activities.
Guided by five key principles:
1. Value: Define value from the customer's perspective.
2. Value Stream: Identify and map out the value stream to understand the flow of materials and information.
3. Flow: Create a smooth flow of processes to produce value.
4. Pull: Only produce what is needed, when it is needed (pull production).
5. Perfection: Continuously improve the process to achieve perfection.

Waste: Any activity that does not add value to the product or service.
Muda (Types of Waste):
- Transportation: Moving products or materials unnecessarily.
- Inventory: Excess materials or products.
- Motion: Unnecessary movement of people or equipment.
- Waiting: Idle time due to equipment downtime or material shortages.
- Overproduction: Producing more than what is needed.
- Overprocessing: Using more resources than necessary.
- Defects: Errors or defects in products or services.
Continuous Improvement: Ongoing effort to improve processes and eliminate waste.

Value Stream Mapping (VSM): Visual representation of the value stream to identify waste and opportunities for improvement.
Kaizen Events: Structured, team-based improvement activities to address specific problems or opportunities.
Total Productive Maintenance (TPM): Proactive maintenance strategy to minimize equipment downtime.
Just-In-Time (JIT) Production: Producing and delivering products just in time to meet customer demand.
Kanban: Visual system to manage inventory and production levels.

Improved Efficiency: Reduced waste and improved productivity.
Cost Savings: Reduced inventory, energy, and labor costs.
Enhanced Customer Satisfaction: Improved quality and responsiveness to customer needs.
Competitive Advantage: Improved agility and responsiveness to changing market conditions.

A systematic approach to identifying and eliminating waste in production processes
Focuses on maximizing value-added activities and minimizing non-value-added activities

Value: Define value from the customer's perspective
Value Stream: Identify and map out the value stream to understand the flow of materials and information
Flow: Create a smooth flow of processes to produce value
Pull: Only produce what is needed, when it is needed
Perfection: Continuously improve the process to achieve perfection

Waste: Any activity that does not add value to the product or service
Muda (Types of Waste):
- Transportation: Moving products or materials unnecessarily
- Inventory: Excess materials or products
- Motion: Unnecessary movement of people or equipment
- Waiting: Idle time due to equipment downtime or material shortages
- Overproduction: Producing more than what is needed
- Overprocessing: Using more resources than necessary
- Defects: Errors or defects in products or services
Continuous Improvement: Ongoing effort to improve processes and eliminate waste

Value Stream Mapping (VSM): Visual representation of the value stream to identify waste and opportunities for improvement
Kaizen Events: Structured, team-based improvement activities to address specific problems or opportunities
Total Productive Maintenance (TPM): Proactive maintenance strategy to minimize equipment downtime
Just-In-Time (JIT) Production: Producing and delivering products just in time to meet customer demand
Kanban: Visual system to manage inventory and production levels

Improved Efficiency: Reduced waste and improved productivity
Cost Savings: Reduced inventory, energy, and labor costs
Enhanced Customer Satisfaction: Improved quality and responsiveness to customer needs
Competitive Advantage: Improved agility and responsiveness to changing market conditions