Lean manufacturing is a methodical process on the removal of waste in an industrial system. Lean also considers waste formed through overload and through disproportion in workloads. Operating from the viewpoint of the customer who uses a product or service, “value” is something that he would be ready to compensate.
Basically, lean is focused on making what puts worth by decreasing everything else. Lean production is a controlling idea derived from Toyota Production System and recognized to be “lean” in the 1990s. TPS is well-known for its concentration on the decrease of original Toyota wastes to expand total customer importance, however there are changing perceptions on how it is attained. Toyota started as a small company and grew into the world’s largest auto company.
There are a number of lean manufacturing principles to be understood in order to apply lean. Without understanding and applying these principles, it will most likely result in disappointment or a lack of commitment from everyone in the organization. The process becomes unsuccessful without commitment.
The following are guiding principles of lean manufacturing:
Continuous improvement is the most critical among lean manufacturing principles. It forms the foundation of lean implementation. Absence of continuous improvement ceases progress. As it implies, there must be constancy as it is necessary in achieving a desirable outcome. Innovations can be big or small as long as it is towards improvement.
This should be a philosophy that is true throughout the organization. Though the focus is on a large scale of enhancement, it should not only center on big ideas but also on the minimal concepts because they can sometimes minor details can also lead to major improvements.
Lean manufacturing is leveled production. The level of every day workload is the basis of this principle. Manufacturing companies wait for what their customers order before manufacturing products. This result to increased distribution time and sometimes dissatisfy customers’ needs.
Some companies produce products based strictly on forecast. There might be excess products not needed by customers. Leveled production lays account on both forecast and history. Pull system utilization is one key factor because it shows the demand.
Respect for Humanity
This lean manufacturing principle is all about human resource—manpower. Companies need people to work for them and so they are also obliged to give fair and good treatment to workers. Respect must always be present. Problems in lean implementation may arise if there is no coherent relationship and communication among personnel. They must feel worthy of the job and be contributors on the achievement of company goals as well.
Produce what is necessary, when it is needed and the quantity needed. Working with leveled production, this works well a pull system. It permits movement and production of parts only when needed.
Quality is built during the manufacturing process—from the design up to the packaging of the product. Making sure that every part is best in quality and free from defects.
— Slimane Zouggari