Lean Production

Definition

Lean manufacturing systems use a systematic approach to identify and eliminate waste through continuous improvement by allowing the flow of the product only when the customer needs it.

Error Free Production

Error free production means first time quality. By stopping production when a defect is detected, defects are prevented from traveling on to the next process, and can be located and solved quickly and efficiently.

Lean Manufacturing Concepts

5S
One Piece Flow (Cell Manufacturing)
Poka Yoke
Single Minute Exchange of Dies (SMED)
Visual Controls
Waste Elimination
Zero Defects

Main objectives to eliminate waste (7 deadly wastes/Mudas)

Some of the key principles of "lean" includes the elimination of waste, and the creation of value added work and efficiency.

Waste of:

Overproduction
Defective Workmanship
Excessive effort
Excess inventory
Waste of conveyance
Waste of motion
Waiting

Matching of lean production process to a lean consumption process

Traditional system

Starts in factory - Ends with customer
Production plan based on demand
Material procurement to meet production plan
Material receipt & inspection
Storage of materials & components (Until required for processing)
Actual production on various stations with stress on maximising production
Assembly, final inspection & packaging
Storage of finished goods.

Closing the gap between customer & factory

Begins at home
Home is the market of sale, the place where the customer lives
Manufacturers to think forward from the order point and shipping dock rather than backward through the factory & value stream
Is most important and feasible in home market of manufacturers
Is a critical challenge for future success.