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.Lean manufacturing or lean production, which is often known simply as "Lean", is a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination.^ Lean Manufacturing also takes care of Value Chain and Flow Production.
  • Six Sigma Blog: Lean Manufacturing 16 January 2010 22:55 UTC www.sixsigmablog.org [Source type: FILTERED WITH BAYES]

^ The ultimate goal is to provide value to the customer through a value creation process that has zero waste.
  • Lean and Green Manufacturing - Blanks Printing & Imaging 16 January 2010 22:55 UTC www.blanks.com [Source type: Reference]

^ Lean Manufacturing is a business initiative to reduce waste in manufactured products.
  • QAD Lean Manufacturing Software, Manufacturing System Software 16 January 2010 22:55 UTC www.qad.com [Source type: FILTERED WITH BAYES]

.Working from the perspective of the customer who consumes a product or service, "value" is defined as any action or process that a customer would be willing to pay for.^ VALUE : what the customer is willing to pay for (ie processes which transform the product, eg : bending, welding, etc).

^ Define value from the customer's perspective .
  • Alberta, Canada - Productivity: Lean Manufacturing 16 January 2010 22:55 UTC albertacanada.com [Source type: FILTERED WITH BAYES]

^ Value is the benefit the customer receives from the product.
  • Work Sample 12 September 2009 12:10 UTC www.umsl.edu [Source type: FILTERED WITH BAYES]

.Basically, lean is centered around creating more value with less work.^ Lean is about doing more with less: .
  • Lean Manufacturing is A Competitive Weapon 16 January 2010 22:55 UTC www.dwassoc.com [Source type: General]

^ With lean manufacturing, less is definitely more.

^ Simply, lean means creating more value for customers with less resources.
  • What is Lean 16 January 2010 22:55 UTC www.lean.org [Source type: FILTERED WITH BAYES]
  • Lean and Green Manufacturing - Blanks Printing & Imaging 16 January 2010 22:55 UTC www.blanks.com [Source type: Reference]

.Lean manufacturing is a generic process management philosophy derived mostly from the Toyota Production System (TPS) (hence the term Toyotism is also prevalent) and identified as "Lean" only in the 1990s.^ Posts Tagged ‘lean production systems’ .
  • Lean Production Systems | Setpoint Systems Blog 12 September 2009 12:10 UTC www.setpointusa.com [Source type: General]

^ Lean Manufacturing philosophy and techniques are rooted in the Toyota Production System (TPS).
  • Become a Lean Enterprise, implement the best practices from the Toyota Production System 16 January 2010 22:55 UTC www.leanmfgcoach.com [Source type: General]

^ Add More Products To lean manufacturing .
  • Amazon.com: lean manufacturing 16 January 2010 22:55 UTC www.amazon.com [Source type: General]

[1] .[2] It is renowned for its focus on reduction of the original Toyota seven wastes in order to improve overall customer value, but there are varying perspectives on how this is best achieved.^ Define value from the customer's perspective .
  • Alberta, Canada - Productivity: Lean Manufacturing 16 January 2010 22:55 UTC albertacanada.com [Source type: FILTERED WITH BAYES]

^ It is renowned for its focus on reduction of the original Toyota 8 wastes in order to improve overall customer value.
  • Lean manufacturing 16 January 2010 22:55 UTC www.bexcellence.org [Source type: FILTERED WITH BAYES]

^ It is renowned for its focus on reduction of the original Toyota seven wastes in order to improve overall customer value, but there are varying perspectives on how this is best achieved.

.The steady growth of Toyota, from a small company to the world's largest automaker,[3] has focused attention on how it has achieved this.^ The steady growth of Toyota, from a small company to the world's largest automaker, has focused attention on how it has achieved this.

^ Toyota's steady growth from a small player to the most valuable and the biggest car company in the world has focused attention upon how it has achieved this, making "Lean manufacturing " a hot topic in management science in the first decade of the 21st century.
  • Lean manufacturing 16 January 2010 22:55 UTC www.bexcellence.org [Source type: FILTERED WITH BAYES]

^ Currently, Toyota is the largest car company worldwide, and the most valuable at that.

.Lean manufacturing is a variation on the theme of efficiency based on optimizing flow; it is a present-day instance of the recurring theme in human history toward increasing efficiency, decreasing waste, and using empirical methods to decide what matters, rather than uncritically accepting pre-existing ideas.^ Lean manufacturing techniques are used to increase profitability by reducing costs.
  • Lean Manufacturing Learning Center 16 January 2010 22:55 UTC www.vorne.com [Source type: General]

^ What methods are used in lean?
  • Lean and the Environment | EPA 16 January 2010 22:55 UTC www.epa.gov [Source type: Academic]

^ Lean Manufacturing focuses on improving manufacturing efficiency through the elimination of waste.
  • Lean Manufacturing for High-speed Production | News | Automation World 16 January 2010 22:55 UTC www.automationworld.com [Source type: FILTERED WITH BAYES]

.As such, it is a chapter in the larger narrative that also includes such ideas as the folk wisdom of thrift, time and motion study, Taylorism, the Efficiency Movement, and Fordism.^ After you view this six sigma area dedicated to learning the true cost of equipment downtime with time and motion study, please visit our company.
  • Lean Manufacturing for Production Managemet.l 16 January 2010 22:55 UTC www.downtimecentral.com [Source type: FILTERED WITH BAYES]

^ These principles include concepts such as built in quality, visual control, just in time, pull system, work leveling, continuous improvement, and teamwork.
  • Lean Manufacturing: Economic Development Classes: Henderson Community College 16 January 2010 22:55 UTC henderson.kctcs.edu [Source type: General]

^ A cluttered workplace can lead to waste which includes time spent looking for things, machine failures, extra motion to avoid various obstacles and increased accidents.
  • MEDA Engineering & Technical Services Limited -- Lean Manufacturing 16 January 2010 22:55 UTC www.medagroup.com [Source type: General]

.Lean manufacturing is often seen as a more refined version of earlier efficiency efforts, building upon the work of earlier leaders such as Taylor or Ford, and learning from their mistakes.^ Learn more about PGPi lean manufacturing and operations consulting .
  • Performance Growth Partners Inc. - Lean Manufacturing Consultant 16 January 2010 22:55 UTC www.performtogrow.com [Source type: General]

^ How can Lean Manufacturing work for you?
  • Lean Manufacturing Consultants Brisbane, improve profit by applying lean principles, lean production techniques 16 January 2010 22:55 UTC www.kaon.com.au [Source type: General]

^ Learn the key lean manufacturing principles.
  • Lean Manufacturing Consultant and Training. Books and Lean Manufacturing Consultancy 16 January 2010 22:55 UTC www.lean-manufacturing.davegrooms.co.uk [Source type: General]
  • Lean Manufacturing Uncovered..Learn The Principal Of Lean Manufacturing Instantly Download PDF Book. 16 January 2010 22:55 UTC www.ebooksforever.net [Source type: General]

Contents

Overview

.Lean principles come from the Japanese manufacturing industry.^ Lean 101 - Principles of Lean Manufacturing .
  • TechHelp - Solutions for Idaho Manufacturers 16 January 2010 22:55 UTC www.techhelp.org [Source type: General]

^ Lean manufacturing training of lean management and lean manufacturing principles .
  • Lean manufacturing training of lean management and lean manufacturing principles 16 January 2010 22:55 UTC www.qualitysolutions.com [Source type: General]

^ Tier One Lean manufacturing Principles .

.The term was first coined by John Krafcik in a Fall 1988 article, "Triumph of the Lean Production System," published in the Sloan Management Review and based on his master's thesis at the MIT Sloan School of Management.^ Lean Production: first steps .

^ Posts Tagged ‘lean production systems’ .
  • Lean Production Systems | Setpoint Systems Blog 12 September 2009 12:10 UTC www.setpointusa.com [Source type: General]

^ Lean Management Systems : Lean management goes  more...
  • Lean Manufacturing - Training Seminars, Resources and Workshops 16 January 2010 22:55 UTC www.training-classes.com [Source type: General]

[4] .Krafcik had been a quality engineer in the Toyota-GM NUMMI joint venture in California before coming to MIT for MBA studies.^ Krafcik had been a quality engineer in the Toyota-GM NUMMI joint venture in California before coming to MIT for MBA studies.

^ In addition, quality, maintenance, human resource professionals, engineers, scientists and students engaged in management studies will gain much by reading this book.
  • Lean Manufacturing | Productivity Press | Lean books| Lean Production | 5S | Six sigma | Toyota Production System 16 January 2010 22:55 UTC www.productivitypress.com [Source type: General]

^ Toyota's engineers looked to Henry Ford (inventor of the assembly line), Taylor (inventor of Modern Management techniques and Industrial Engineering), and Dr. W. Edwards Deming (Father of Modern Quality Management).
  • Lean Manufacturing 16 January 2010 22:55 UTC www.pqa.net [Source type: FILTERED WITH BAYES]

.Krafcik's research was continued by the International Motor Vehicle Program (IMVP) at MIT, which produced the international best-seller book co-authored by James Womack, Daniel Jones, and Daniel Roos called The Machine That Changed the World.[1] A complete historical account of the IMVP and how the term "lean" was coined is given by Holweg (2007) [5].^ "Lean is about people and this book is the BEST about people and lean."
  • Amazon.com: The Best Lean Manufacturing Books 16 January 2010 22:55 UTC www.amazon.com [Source type: General]

^ Womack who led the MIT research team that coined the term "lean" 20 years ago.
  • Womack Advances Lean Management as Successor to Traditional Management| Reuters 9 October 2009 8:58 UTC www.reuters.com [Source type: News]
  • Orlando Conference Advances Lean Management as Successor to Traditional Management| Reuters 9 October 2009 8:58 UTC www.reuters.com [Source type: News]

^ Lean Manufacturing is a term coined in the James P. Womack book, The Machine That Changed the World , based largely on his observations of the Toyota Production System.
  • Lean Manufacturing and Lean Enterprise 16 January 2010 22:55 UTC continental-design.com [Source type: FILTERED WITH BAYES]

.For many, Lean is the set of "tools" that assist in the identification and steady elimination of waste (muda).^ Lean is about eliminating waste.
  • Lean Manufacturing is A Competitive Weapon 16 January 2010 22:55 UTC www.dwassoc.com [Source type: General]

^ Lean thinking is in the relentless elimination of waste.
  • Lean Manufacturing: Converting to Collaborative Lean Flow 16 January 2010 22:55 UTC rmdonovan.web6.hubspot.com [Source type: FILTERED WITH BAYES]

^ Lean is continuous waste elimination.
  • Operational Excellence | Lean Manufacturing and Pharma: An Interview with Phil Emard | Pharmaceutical Manufacturing 16 January 2010 22:55 UTC www.pharmamanufacturing.com [Source type: General]

.As waste is eliminated quality improves while production time and cost are reduced.^ As wasteful activities are eliminated, the elapsed time to manufacture a product is reduced.
  • Lean manufacturing can save American manufacturing 16 January 2010 22:55 UTC www.reliableplant.com [Source type: FILTERED WITH BAYES]

^ Reduce or eliminate waste and improve flow .
  • Alberta, Canada - Productivity: Lean Manufacturing 16 January 2010 22:55 UTC albertacanada.com [Source type: FILTERED WITH BAYES]

^ Reduces production waste and improves the quality of product .
  • Lean Printing Office uses Lean Manufacturing, Lean Office and Best Practices to reduce costs for printing and packaging companies 16 January 2010 22:55 UTC www.profectus.com [Source type: General]

.Examples of such "tools" are Value Stream Mapping, Five S, Kanban (pull systems), and poka-yoke (error-proofing).^ We’re doing joint value stream maps with customers, called value chain mapping, so we can see on both sides of the table,” he said.

^ Once Value Stream Mapping has been completed, a number of areas for improvement are typically identified that will have maximum impact on the area being analyzed.
  • Lean Manufacturing Training 16 January 2010 22:55 UTC www.paulnugent.com [Source type: General]

^ Value stream mapping .
  • Lean Manufacturing 16 January 2010 22:55 UTC leanmanufacture.net [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing Concepts 16 January 2010 22:55 UTC leanmanufacture.net [Source type: General]

.There is a second approach to Lean Manufacturing, which is promoted by Toyota, in which the focus is upon improving the "flow" or smoothness of work, thereby steadily eliminating mura ("unevenness") through the system and not upon 'waste reduction' per se.^ Lean Manufacturing is an initiative focused on eliminating all waste in manufacturing processes.
  • Lean Manufacturing | FormaShape 16 January 2010 22:55 UTC www.formashape.com [Source type: General]

^ Lean manufacturing is a production concept aimed at eliminating waste.
  • Questions about Lean Manufacturing - Ask.com 16 January 2010 22:55 UTC www.ask.com [Source type: General]

^ Lean manufacturing: The practical approach to productivity .
  • Lean manufacturing: The practical approach to productivity 16 January 2010 22:55 UTC www.reliableplant.com [Source type: FILTERED WITH BAYES]

.Techniques to improve flow include production leveling, "pull" production (by means of kanban) and the Heijunka box.^ Techniques to improve flow include production leveling , "pull" production (by means of kanban) and the Heijunka box.
  • Lean manufacturing 16 January 2010 22:55 UTC www.bexcellence.org [Source type: FILTERED WITH BAYES]

^ Techniques to improve flow include production levelling, ‘pull’ production (by means of kanban ) and the Heijunka box .

^ Techniques to improve flow include production leveling , "pull" production (by means of kanban ) and the Heijunka box .

.This is a fundamentally different approach to most improvement methodologies which may partially account for its lack of popularity.^ This is a fundamentally different approach to most improvement methodologies which may partially account for its lack of popularity.

^ The lean manufacturing approach is the most comprehensive of the popular production management improvement initiatives because it addresses product, process, and human related issues in the production system.
  • Lean Manufacturing - October 20-22 - Blacksburg, VA 16 January 2010 22:55 UTC www.cpe.vt.edu [Source type: FILTERED WITH BAYES]

^ Over the past several decades, advances in lean production techniques have provided models for performance improvement that may be more effective and more efficient than traditional approaches.
  • RECORDED WEBINAR: Reducing Errors in the Clinical Laboratory: A Lean Production System Approach 12 September 2009 12:10 UTC educationwebinar.bd.com [Source type: FILTERED WITH BAYES]

.The difference between these two approaches is not the goal itself, but rather the prime approach to achieving it.^ These are two distinctly different things.
  • The Lean Manufacturing Handbook 16 January 2010 22:55 UTC continental-design.com [Source type: FILTERED WITH BAYES]

^ The difference between these two approaches is not the goal but the prime approach to achieving it .
  • Lean manufacturing 16 January 2010 22:55 UTC www.bexcellence.org [Source type: FILTERED WITH BAYES]

^ The main difference between the two concepts is in approach.
  • Work Sample 12 September 2009 12:10 UTC www.umsl.edu [Source type: FILTERED WITH BAYES]

.The implementation of smooth flow exposes quality problems that already existed, and thus waste reduction naturally happens as a consequence.^ The implementation of smooth flow exposes quality problems which always existed and thus waste reduction naturally happens as a consequence.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ The implementation of smooth flow exposes quality problems which already existed and thus waste reduction naturally happens as a consequence.

^ Benefits realized by companies that implemented lean manufacturing include: 1) waste reduction, and therefore, production cost reduction; 2) shorter manufacturing cycle times; 3) lower manpower requirements; 4) minimal inventories; 5) higher equipment utilization and manufacturing capacity; 6) improved cash flow; 7) higher product quality and reliability; and 8) better customer service.
  • Lean Manufacturing or Lean Production 16 January 2010 22:55 UTC www.siliconfareast.com [Source type: General]

.The advantage claimed for this approach is that it naturally takes a system-wide perspective, whereas a waste focus sometimes wrongly assumes this perspective.^ The advantage claimed for this approach is that it naturally takes a system-wide perspective whereas a 'waste' focus has this perspective, sometimes wrongly, assumed.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ The advantage claimed for this approach is that it naturally takes a system-wide perspective whereas a 'waste' focus has this perspective assumed.
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ There is a second approach to Lean Manufacturing which is promoted by Toyota in which the focus is upon implementing the 'flow' or smoothness of work (opposite of mura, unevenness) through the system and not upon 'waste reduction'.
  • Lean manufacturing 16 January 2010 22:55 UTC www.bexcellence.org [Source type: FILTERED WITH BAYES]

.Both Lean and TPS can be seen as a loosely connected set of potentially competing principles whose goal is cost reduction by the elimination of waste.^ Lean is about eliminating waste.
  • Lean Manufacturing is A Competitive Weapon 16 January 2010 22:55 UTC www.dwassoc.com [Source type: General]

^ The key focus of TPS is to eliminate waste.

^ Lean thinking is in the relentless elimination of waste.
  • Lean Manufacturing: Converting to Collaborative Lean Flow 16 January 2010 22:55 UTC rmdonovan.web6.hubspot.com [Source type: FILTERED WITH BAYES]

[6] .These principles include: Pull processing, Perfect first-time quality, Waste minimization, Continuous improvement, Flexibility, Building and maintaining a long term relationship with suppliers, Autonomation, Load leveling and Production flow and Visual control.^ This includes both processing and queue time.
  • Lean manufacturing definition | Lean Manufacturing 16 January 2010 22:55 UTC www.beyondlean.com [Source type: FILTERED WITH BAYES]

^ In minimizing these wastes, the principles of lean manufacturing employ strategies that focus on improving the production process.

^ Real-time process controls .
  • Lean Manufacturing Training and Consulting 16 January 2010 22:55 UTC www.tqsconsulting.com [Source type: FILTERED WITH BAYES]

.The disconnected nature of some of these principles perhaps springs from the fact that the TPS has grown pragmatically since 1948 as it responded to the problems it saw within its own production facilities.^ The disconnected nature of some of these principles perhaps springs from the fact that the TPS has grown pragmatically as it responded to the problems it saw within its own production facilities.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ These concepts must be understood and embraced by the employees who build the products; they own the process.
  • Paulson Training Programs, Inc. - Lean Manufacturing 16 January 2010 22:55 UTC store.paulsontraining.com [Source type: General]

^ Fundamental- Involving basic facts or principles; far-reaching and thoroughgoing in effect especially on the nature of something.

.Thus what one sees today is the result of a 'need' driven learning to improve where each step has built on previous ideas and not something based upon a theoretical framework.^ Thus what one sees today is the result of a 'need' driven learning to improve where each step has built on previous ideas and not something based upon a theoretical framework.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]
  • About Lean Manufacturing 16 January 2010 22:55 UTC www.pinnacle-strategies.com [Source type: FILTERED WITH BAYES]

^ It is perhaps best stated by Edward Deming, as “the need to improve constantly and forever the system of production and service to improve quality and productivity and thus constantly decrease costs.” .

^ Since all views are partial, seeing one extreme consider the arguments of another extreme is a step toward greater understanding.
  • Lean Manufacturing Blog, Kaizen Articles and Advice | Gemba Panta Rei 12 September 2009 12:10 UTC www.gembapantarei.com [Source type: FILTERED WITH BAYES]

.Toyota's view is that the main method of Lean is not the tools, but the reduction of three types of waste: muda ("non-value-adding work"), muri ("overburden"), and mura ("unevenness"), to expose problems systematically and to use the tools where the ideal cannot be achieved.^ Excess processing : creating unnecessary/ non-value adding work.
  • Lean Manufacturing Concepts 16 January 2010 22:55 UTC leanmanufacture.net [Source type: General]

^ Eliminate waste and non-value-added activity (NVA).
  • Lean manufacturing 16 January 2010 22:55 UTC www.bexcellence.org [Source type: FILTERED WITH BAYES]

^ Reducing non-value adding activities .
  • Improve NZ Lean Manufacturing Programs 16 January 2010 22:55 UTC www.improvegroup.com.au [Source type: FILTERED WITH BAYES]

.From this perspective, the tools are workarounds adapted to different situations, which explains any apparent incoherence of the principles above.^ Thus the 'tools' are adapted to different situations which explain any apparent incoherence of the 'principles' above.
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Thus the 'tools' are adapted to different situations which explains any apparent incoherence of the 'principles' above.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ Some service industries have found the same principles apply, although the use of lean manufacturing tools is different.
  • Applying Lean Manufacturing In The Service Industry 16 January 2010 22:55 UTC www.buzzle.com [Source type: FILTERED WITH BAYES]

Origins

.Also known as the flexible mass production, the TPS has two pillar concepts: Just-in-time (JIT) or "flow", and "autonomation" (smart automation).^ This leads to things like JIT (Just in time) manufactur...
  • Questions about Lean Manufacturing - Ask.com 16 January 2010 22:55 UTC www.ask.com [Source type: General]

^ The advantages of a just-in-time production system are: .
  • S-Cool | Lean Production 12 September 2009 12:10 UTC www.s-cool.co.uk [Source type: FILTERED WITH BAYES]

^ In industrial engineering, the time between completion of two discrete units of production.
  • Lean manufacturing definition | Lean Manufacturing 16 January 2010 22:55 UTC www.beyondlean.com [Source type: FILTERED WITH BAYES]

[7] .Adherents of the Toyota approach would say that the smooth flowing delivery of value achieves all the other improvements as side-effects.^ Adherents of the Toyota approach would say that 'flow' delivery of 'value' does all these improvements as a side-effect.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Adherence of the Toyota approach would say that 'flow' delivery of 'value' does all these improvements as a side-effect.

^ The 'flow' (or smoothness) based approach aims to achieve JIT by removing the variation caused by work scheduling and thereby provide a driver, rationale or target and priorities for implementation, using a variety of techniques.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

.If production flows perfectly then there is no inventory; if customer valued features are the only ones produced, then product design is simplified and effort is only expended on features the customer values.^ There are no production schedulers.
  • Optimized Lean Manufacturing 16 January 2010 22:55 UTC www.epictech.com [Source type: Reference]

^ Value is the benefit the customer receives from the product.
  • Work Sample 12 September 2009 12:10 UTC www.umsl.edu [Source type: FILTERED WITH BAYES]

^ Make value flow at the pull of the customer .
  • Superfactory - Lean Manufacturing Resources 16 January 2010 22:55 UTC www.superfactory.com [Source type: Reference]

.The other of the two TPS pillars is the very human aspect of autonomation, whereby automation is achieved with a human touch.^ The TPS has two pillar concepts: JIT (flow) and autonomation (smart automation).
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ The other of the two TPS pillars is the very human aspect of 'autonomation' whereby automation is achieved with a human touch.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]

^ The other of the two TPS pillars is the very human aspect of ' autonomation ' whereby automation is achieved with a human touch.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

[8] .The "human touch" here meaning to automate so that the machines/systems are designed to aid humans in focusing on what the humans do best.^ If the processes are not customer-focused and efficient in design, then automation simply speeds up the pace at which errors are created.
  • Lean manufacturing and IT: backlogs as inventory | University ITSM 16 January 2010 22:55 UTC itsm.is.wfu.edu [Source type: FILTERED WITH BAYES]

^ Bring a touch of human intelligence to a machine so that this one shut down automatically if a problem occurs.
  • LEAN KEY | Kaizen & Lean manufacturing 16 January 2010 22:55 UTC www.lean-key.com [Source type: FILTERED WITH BAYES]

^ Automation with a human touch falls within this principle.

.This aims, for example, to give the machines enough intelligence to recognize when they are working abnormally and flag this for human attention.^ This aims to give the machines enough 'intelligence' to recognize when they are working abnormally and flag this for human attention.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ This aims to give the machines enough 'intelligence' to recognise when they are working abnormally and flag this for human attention.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]

^ "The same is true in software, where you have the added benefit of being able to give some of your work to a computer, which can process it more reliably and quickly than a human."
  • Bringing 'Lean' Principles to Service Industries — HBS Working Knowledge 12 September 2009 12:10 UTC hbswk.hbs.edu [Source type: FILTERED WITH BAYES]

.Thus, in this case, humans would not have to monitor normal production and only have to focus on abnormal, or fault, conditions.^ Thus humans do not have to monitor normal production and only have to focus on abnormal, or fault, conditions.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ VISUAL FACTORY SYSTEMS The visual factory generates techniques that share important information and make distinctions between normal and abnormal production and quality conditions.
  • Lean Manufacturing -- Lean Enterprises 16 January 2010 22:55 UTC www.morainevalley.edu [Source type: General]

^ Technical standards, such as product specifications, validated settings and production conditions, can only change following a change control exercise.
  • Lean Manufacturing practice in a cGMP environment - Pharmaceutical Technology 16 January 2010 22:55 UTC pharmtech.findpharma.com [Source type: FILTERED WITH BAYES]

.Lean implementation is therefore focused on getting the right things to the right place at the right time in the right quantity to achieve perfect work flow, while minimizing waste and being flexible and able to change.^ Lean is about speed and getting it right the first time.
  • Lean Manufacturing is A Competitive Weapon 16 January 2010 22:55 UTC www.dwassoc.com [Source type: General]

^ Material replenishment design and implementation Materials need to be in the right place, in the right quantity at the right time.
  • Lean Manufacturing Consultants Brisbane, improve profit by applying lean principles, lean production techniques 16 January 2010 22:55 UTC www.kaon.com.au [Source type: General]

^ ARI-Jackson Manufacturing's focus on getting the right things, to the right place, at the right time, in the right quantity to achieve perfect work flow while minimizing waste and being flexible.
  • ARI-Jackson Manufacturing's Lean Manufacturing 16 January 2010 22:55 UTC www.ari-jackson.com [Source type: General]

.These concepts of flexibility and change are principally required to allow production leveling, using tools like SMED, but have their analogues in other processes such as research and development (R&D).^ These concepts of flexibility and change are principally required to allow production leveling, using tools like SMED , but have their analogues in other processes such as R&D. The flexibility and ability to change are not open-ended, and therefore often expensive, capability requirements.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ These concepts of flexibility and change are principally required to allow production levelling, using tools like SMED , but have their analogues in other processes such as R&D. The flexibility and ability to change are not open-ended, and therefore often expensive, capability requirements.

^ This included using leans tools such as; .
  • » Implementing Lean Production 12 September 2009 12:10 UTC www.bizmanualz.com [Source type: General]

.The flexibility and ability to change are within bounds and not open-ended, and therefore often not expensive capability requirements.^ These concepts of flexibility and change are principally required to allow production levelling, using tools like SMED , but have their analogues in other processes such as R&D. The flexibility and ability to change are not open-ended, and therefore often expensive, capability requirements.

^ These concepts of flexibility and change are principally required to allow production leveling, using tools like SMED, but have their analogues in other processes such as R&D. The flexibility and ability to change are not open-ended, and therefore often expensive, capability requirements.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ It is about getting the right things, to the right people, at the right place, at the right time, in the right quantities while minimizing waste and being flexible and open to change.
  • Lean Enterprise Tools 16 January 2010 22:55 UTC www.techhelp.org [Source type: FILTERED WITH BAYES]

.More importantly, all of these concepts have to be understood, appreciated, and embraced by the actual employees who build the products and therefore own the processes that deliver the value.^ More importantly, all of these concepts have to be understood, appreciated, and embraced by the actual employees who build the products and therefore own the processes.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ More importantly, these concepts should be understood, appreciated, and embraced by the actual employees who build the products, therefore owning the processes.
  • Lean Manufacturing Implementation | Lean Manufacturing Training 16 January 2010 22:55 UTC www.thomasgroup.com [Source type: FILTERED WITH BAYES]

^ Another mistake is managers frequently overlook that lean techniques need to be applied to all processes that helps support production, not just production itself.
  • Implementing Lean Manufacturing 16 January 2010 22:55 UTC www.manufacturing.net [Source type: FILTERED WITH BAYES]
  • Implementing Lean Manufacturing 16 January 2010 22:55 UTC www.manufacturing.net [Source type: FILTERED WITH BAYES]

.The cultural and managerial aspects of Lean are possibly more important than the actual tools or methodologies of production itself.^ Read more about lean production: .
  • What is lean production? - Definition from Whatis.com - see also: lean management, lean manufacturing 12 September 2009 12:10 UTC searchcio.techtarget.com [Source type: Academic]

^ Add More Products To lean manufacturing .
  • Amazon.com: lean manufacturing 16 January 2010 22:55 UTC www.amazon.com [Source type: General]

^ It’s more of the culture aspects.
  • How to carry lean management in logistics and supply chain - China automotive news 9 October 2009 8:58 UTC autonews.gasgoo.com [Source type: General]

.There are many examples of Lean tool implementation without sustained benefit, and these are often blamed on weak understanding of Lean throughout the whole organization.^ How to implement Lean What are the benefits of Lean?

^ There is a collection of concepts that are often called the "lean tools" or "lean principles".
  • beverlybucks@yahoo.com - Lean Manufacturing Training - Standardized Operations 16 January 2010 22:55 UTC www.ideamarketers.com [Source type: General]

^ There are many examples of Lean tool implementation without sustained benefit and these are often blamed on weak understanding of Lean in the organisation.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]

.Lean aims to make the work simple enough to understand, do and manage.^ Making the lean manufacturing management commitment .

^ Lean aims to make the work simple enough to understand, to do and to manage.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Thus, lean managers focus on responsibility and ownership, which means keying on "doing the right thing," as opposed to authority, which deals with who has the right to make certain decisions.
  • LEAN.org - Lean Enterprise Institute| Lean Production | Lean Manufacturing | LEI | Lean Services | 16 January 2010 22:55 UTC www.lean.org [Source type: General]
  • LEAN.org - Lean Enterprise Institute| Lean Production | Lean Manufacturing | LEI | Lean Services | 16 January 2010 22:55 UTC leanglobalnetwork.org [Source type: General]

.To achieve these three goals at once there is a belief held by some that Toyota's mentoring process (loosely called Senpai and Kohai), is one of the best ways to foster Lean Thinking up and down the organizational structure.^ Is there another way to get to your goals?

^ JW. There are really two ways to think about leaning the sales process.
  • Lean Management and the Role of Lean Leadership Webinar Answers 9 October 2009 8:58 UTC pages.citebite.com [Source type: FILTERED WITH BAYES]

^ Finally, there is an understanding that Toyota's mentoring process (loosely called Senpai and Kohai relationship) so strongly supported in Japan is one of the ways to foster Lean Thinking up and down the organizational structure.
  • Superfactory - Lean Manufacturing Resources 16 January 2010 22:55 UTC www.superfactory.com [Source type: Reference]

.This is the process undertaken by Toyota as it helps its suppliers improve their own production.^ Another mistake is managers frequently overlook that lean techniques need to be applied to all processes that helps support production, not just production itself.
  • Implementing Lean Manufacturing 16 January 2010 22:55 UTC www.manufacturing.net [Source type: FILTERED WITH BAYES]
  • Implementing Lean Manufacturing 16 January 2010 22:55 UTC www.manufacturing.net [Source type: FILTERED WITH BAYES]

^ Opinions differ as to whether lean manufacturing means strict adherence to the Toyota Production System model, or whether any combination of process improvements that address these goals is also lean.
  • Mazak Process 16 January 2010 22:55 UTC www.mazakusa.com [Source type: General]

^ These skilled, seasoned veterans in assembly, product design and production engineering all work together to help us constantly rethink and refine our products and our process.
  • Discover Solenoids: Lean Manufacturing Discover Solenoids: Lean Manufacturing 16 January 2010 22:55 UTC www.dormeyersolenoids.com [Source type: General]

.The closest equivalent to Toyota's mentoring process is the concept of "Lean Sensei", which encourages companies, organizations, and teams to seek outside, third-party experts, who can provide unbiased advice and coaching, (see Womack et al., Lean Thinking, 1998).^ The closest equivalent to Toyota's mentoring process is the concept of Lean Sensei, which encourages companies, organizations, and teams to seek out outside, third-party "Sensei" that can provide unbiased advice and coaching, as indicated in Jim Womack's Lean Thinking book.
  • Superfactory - Lean Manufacturing Resources 16 January 2010 22:55 UTC www.superfactory.com [Source type: Reference]

^ The closest equivalent to Toyota's mentoring process is the concept of Lean Sensei, which encourages companies, organizations, and teams to seek out outside, third-party "Sensei" that can provide unbiased advice and coaching, (see Womack et al, Lean Thinking, 1998).
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Toyota develops Lean thinking .
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

.There have been recent attempts to link Lean to Service Management, perhaps one of the most recent and spectacular of which was London Heathrow Airport's Terminal 5. This particular case provides a graphic example of how care should be taken in translating successful practices from one context (production) to another (services), expecting the same results.^ Lean manufacturing: The practical approach to productivity .
  • Lean manufacturing: The practical approach to productivity 16 January 2010 22:55 UTC www.reliableplant.com [Source type: FILTERED WITH BAYES]

^ Lean management is one answer to that question.
  • Telecommunications Extranet by McKinsey & Company 9 October 2009 8:58 UTC telecoms.mckinsey.com [Source type: FILTERED WITH BAYES]

^ One manufacturing concept stands out as most successful: the concept of lean.
  • lean manufacturing Resources | ZDNet 16 January 2010 22:55 UTC updates.zdnet.com [Source type: General]
  • Manufacturing.net 16 January 2010 22:55 UTC whitepapers.manufacturing.net [Source type: General]
  • Lean Manufacturing: Definition and additional resources from BNET 16 January 2010 22:55 UTC dictionary.bnet.com [Source type: FILTERED WITH BAYES]

.In this case the public perception is more of a spectacular failure, than a spectacular success, resulting in potentially an unfair tainting of the lean manufacturing philosophies [9].^ Strategies for lean manufacturing success .

^ Add More Products To lean manufacturing .
  • Amazon.com: lean manufacturing 16 January 2010 22:55 UTC www.amazon.com [Source type: General]

^ With lean manufacturing, less is definitely more.

A brief history of waste reduction thinking

.The avoidance and then lateral removal of waste has a long history, and as such this history forms much of the basis of the philosophy now known as "Lean". In fact many of the concepts now seen as key to lean have been discovered and rediscovered over the years by others in their search to reduce waste.^ Many of the key concepts and principles are ...
  • The Sixth Sigma - Lean Manufacturing Concepts 16 January 2010 22:55 UTC www.sixthsigma.com [Source type: Academic]

^ Forms of Waste The greatest fact about the Lean process is its simplicity.
  • http://www.mhia.org/news/industry/7076/the-lean-process-and-its-impact-on-manufacturing-and-distribution 16 January 2010 22:55 UTC www.mhia.org [Source type: News]

^ Lean: three key concepts .
  • Multiple paths to lean - 2002-11-01 07:00:00 | Manufacturing Business Technology 16 January 2010 22:55 UTC www.mbtmag.com [Source type: FILTERED WITH BAYES]

Pre-20th century

The printer Benjamin Franklin contributed greatly to waste reduction thinking
.Most of the basic goals of lean manufacturing are common sense, and documented examples can be seen as early as Benjamin Franklin.^ This is where the principles of lean manufacturing are most helpful.

^ Lean manufacturing basics explained .

^ For the most part, Lean is common Industrial Engineering sense.
  • LEAN MANUFACTURING 16 January 2010 22:55 UTC www.iienet2.org [Source type: FILTERED WITH BAYES]

.Poor Richard's Almanac says of wasted time, "He that idly loses 5s. worth of time, loses 5s., and might as prudently throw 5s.^ Poor Richard's Almanack says of wasted time, "He that idly loses 5s.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Business Management Info - Lean Manufacturing History 16 January 2010 22:55 UTC www.grizmo.com [Source type: FILTERED WITH BAYES]

^ Remember what Poor Richard says, 'Buy what thou hast no need of, and ere long thou shalt sell thy necessaries.'
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
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^ If you lose five shillings worth of time, you lose five shillings worth of money.

into the river." .He added that avoiding unnecessary costs could be more profitable than increasing sales: "A penny saved is two pence clear.^ Anything more than a marginal increase in shipping costs is unikely.
  • Business Lean 16 January 2010 22:55 UTC blog.kanban.com [Source type: General]

^ He added that avoiding unnecessary costs could be more profitable than increasing sales: "A penny saved is two pence clear.
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ "The same is true in software, where you have the added benefit of being able to give some of your work to a computer, which can process it more reliably and quickly than a human."
  • Bringing 'Lean' Principles to Service Industries — HBS Working Knowledge 12 September 2009 12:10 UTC hbswk.hbs.edu [Source type: FILTERED WITH BAYES]

.A pin a-day is a groat a-year.^ A pin a-day is a groat a-year.
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ A pin a day is a groat a year.

^ A pin a-day is a great a-year.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

Save and have."
.Again Franklin's The Way to Wealth says the following about carrying unnecessary inventory.^ Again Franklin's The Way to Wealth says the following about carrying unnecessary inventory.
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

."You call them goods; but, if you do not take care, they will prove evils to some of you.^ However, you have to give these so-called goods some care if you do not want them to give you some evils.

^ "You call them goods; but, if you do not take care, they will prove evils to some of you.
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Here are some steps you can take to introduce lean principles into your operation: .
  • Lean Manufacturing Principles Yield Production Benefits 16 January 2010 22:55 UTC www.missouribusiness.net [Source type: FILTERED WITH BAYES]

.You expect they will be sold cheap, and, perhaps, they may [be bought] for less than they cost; but, if you have no occasion for them, they must be dear to you.^ You expect they will be sold cheap, and, perhaps, they may [be bought] for less than they cost; but, if you have no occasion for them, they must be dear to you.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ If you're lucky, you'll be able to dispose of the excesses, but they won't likely be sold at their original price because, well, they'll be considered old stocks or overruns.

^ The aberration is caused by labor variance, and the associated absorption of overhead (to reduce inventory you must, for some period of time, produce less than you ship).
  • Transitioning to Lean Manufacturing - Lean Management Article 16 January 2010 22:55 UTC www.handsongroup.com [Source type: FILTERED WITH BAYES]

.Remember what Poor Richard says, 'Buy what thou hast no need of, and ere long thou shalt sell thy necessaries.'^ Remember what Poor Richard says, 'Buy what thou hast no need of, and ere long thou shalt sell thy necessaries.'
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Business Management Info - Lean Manufacturing History 16 January 2010 22:55 UTC www.grizmo.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Levinson Productivity Systems, P.C. Vision and Mission Statement "To sell raw materials and buy finished goods makes one poor; to buy raw materials and sell finished goods makes one rich."
  • Levinson Productivity Systems, P.C. 16 January 2010 22:55 UTC ct-yankee.com [Source type: FILTERED WITH BAYES]

^ Poor Richard's Almanack says of wasted time, "He that idly loses 5s.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

.In another place he says, 'Many have been ruined by buying good penny worths'." Henry Ford cited Franklin as a major influence on his own business practices, which included Just-in-time manufacturing.^ Henry Ford cited Franklin as a major influence on his own business practices, which included Just-in-time manufacturing.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ In another place he says, 'Many have been ruined by buying good penny worths'."
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Ford is considered by many to be the first practitioner of Just In Time and Lean Manufacturing.
  • Lean Manufacturing History 16 January 2010 22:55 UTC www.strategosinc.com [Source type: FILTERED WITH BAYES]

.The concept of waste being built into jobs and then taken for granted was noticed by motion efficiency expert Frank Gilbreth, who saw that masons bent over to pick up bricks from the ground.^ The concept of waste being built into jobs and then taken for granted was noticed by motion efficiency expert Frank Gilbreth , who saw that masons bent over to pick up bricks from the ground.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ The concept of waste being built into jobs and then taken for granted was noticed by motion efficiency expert Frank Gilbreth, who saw that masons bent over to pick up bricks from the ground.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]

^ The bricklayer was therefore lowering and raising his entire upper body to get a 5 pound (2.3 kg) brick but this inefficiency had been built into the job through long practice.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

.The bricklayer was therefore lowering and raising his entire upper body to pick up a 2.3 kg (5 lb.^ The bricklayer was therefore lowering and raising his entire upper body to get a 5 pound (2.3 kg) brick but this inefficiency had been built into the job through long practice.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

) brick, and this inefficiency had been built into the job through long practice. .Introduction of a non-stooping scaffold, which delivered the bricks at waist level, allowed masons to work about three times as quickly, and with less effort.^ Introduction of a non-stooping scaffold, which delivered the bricks at waist level, allowed masons to work about three times as quickly, and with less effort.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ This is almost three times of the effort and cost .
  • Lean manufacturing, Inventory and Work In Progress (WIP) 16 January 2010 22:55 UTC www.learnleanblog.com [Source type: General]

^ Our processes need to be set up so this information is available quickly and we should build the right models to automate this work on some level so these decisions can be made with minimal effort.
  • How to carry lean management in logistics and supply chain - China automotive news 9 October 2009 8:58 UTC autonews.gasgoo.com [Source type: General]

20th century

.Frederick Winslow Taylor, the father of scientific management, introduced what are now called standardization and best practice deployment.^ Frederick Winslow Taylor, the father of scientific management, introduced what are now called standardization and best practice deployment.

^ He called his ideas Scientific Management.
  • Lean Manufacturing History 16 January 2010 22:55 UTC www.strategosinc.com [Source type: FILTERED WITH BAYES]

^ Frederick Winslow Taylor , the father of scientific management, introduced what are now called standardization and best practice deployment: "And whenever a workman proposes an improvement, it should be the policy of the management to make a careful analysis of the new method, and if necessary conduct a series of experiments to determine accurately the relative merit of the new suggestion and of the old standard.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

.In his Principles of Scientific Management, (1911), Taylor said: "And whenever a workman proposes an improvement, it should be the policy of the management to make a careful analysis of the new method, and if necessary conduct a series of experiments to determine accurately the relative merit of the new suggestion and of the old standard.^ And whenever the new method is found to be markedly superior to the old, it should be adopted as the standard for the whole establishment" ( Principles of Scientific Management , 1911).
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ When you involve improvement in your proposal, the policy of the management is the only one that can make a thorough and careful analysis of the new method.

^ Frederick Winslow Taylor, the father of scientific management, introduced what are now called standardization and best practice deployment: "And whenever a workman proposes an improvement, it should be the policy of the management to make a careful analysis of the new method, and if necessary conduct a series of experiments to determine accurately the relative merit of the new suggestion and of the old standard.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Business Management Info - Lean Manufacturing History 16 January 2010 22:55 UTC www.grizmo.com [Source type: FILTERED WITH BAYES]

.And whenever the new method is found to be markedly superior to the old, it should be adopted as the standard for the whole establishment."^ And whenever the new method is found to be markedly superior to the old, it should be adopted as the standard for the whole establishment" ( Principles of Scientific Management , 1911).
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ And whenever the new method is found to be markedly superior to the old, it should be adopted as the standard for the whole establishment" (Principles of Scientific Management, 1911).
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ The final selection of manufacturing system concept(s) to be adopted for further consideration or development should be based upon analysis performed in conformance with established selection criteria.
  • Thinking of Lean Manufacturing Systems 16 January 2010 22:55 UTC www.sae.org [Source type: FILTERED WITH BAYES]

.Taylor also warned explicitly against cutting piece rates (or, by implication, cutting wages or discharging workers) when efficiency improvements reduce the need for raw labor: "…after a workman has had the price per piece of the work he is doing lowered two or three times as a result of his having worked harder and increased his output, he is likely entirely to lose sight of his employer's side of the case and become imbued with a grim determination to have no more cuts if soldiering [marking time, just doing what he is told] can prevent it."^ Taylor also warned explicitly against cutting piece rates (or, by implication, cutting wages or discharging workers) when efficiency improvements reduce the need for raw labor: "…after a workman has had the price per piece of the work he is doing lowered two or three times as a result of his having worked harder and increased his output, he is likely entirely to lose sight of his employer's side of the case and become imbued with a grim determination to have no more cuts if soldiering [marking time, just doing what he is told] can prevent it."
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ The result was Time Study and standardized work.
  • Lean Manufacturing History 16 January 2010 22:55 UTC www.strategosinc.com [Source type: FILTERED WITH BAYES]

^ This leads to things like JIT (Just in time) manufactur...
  • Questions about Lean Manufacturing - Ask.com 16 January 2010 22:55 UTC www.ask.com [Source type: General]

.Shigeo Shingo, the best-known exponent of single minute exchange of die (SMED) and error-proofing or poka-yoke, cites Principles of Scientific Management as his inspiration.^ SMED: Single Minute Exchange of Die; changing a die on a forming or stamping machine in a minute or less.
  • Online quality chart generators - Seven basic quality management tools, AM Manufacturing - Lean Manufacturing 2 16 January 2010 22:55 UTC www.qtcharts.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing 16 January 2010 22:55 UTC www.slideshare.net [Source type: Reference]

^ Shigeo Shingo , the best-known exponent of single-minute exchange of die ( SMED ) and error-proofing or poka-yoke, cites Principles of Scientific Management as his inspiration (Andrew Dillon, translator, 1987.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ SMED Single Minute Exchange of Die, The method finalized by Shigeo Shingo with Toyota to reduce time of tool changes.
  • LEAN KEY | Kaizen & Lean manufacturing 16 January 2010 22:55 UTC www.lean-key.com [Source type: FILTERED WITH BAYES]

[10]
.American industrialists recognized the threat of cheap offshore labor to American workers during the 1910s, and explicitly stated the goal of what is now called lean manufacturing as a countermeasure.^ American industrialists recognized the threat of cheap offshore labor to American workers during the 1910s, and explicitly stated the goal of what is now called lean manufacturing as a countermeasure.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ The goal of lean manufacturing is to eliminate waste.
  • Lean Manufacturing Overview 130 - Quality Training 16 January 2010 22:55 UTC www.toolingu.com [Source type: Reference]

^ Goals of lean manufacturing (1 slide) .

.Henry Towne, past President of the American Society of Mechanical Engineers, wrote in the Foreword to Frederick Winslow Taylor's Shop Management (1911), "We are justly proud of the high wage rates which prevail throughout our country, and jealous of any interference with them by the products of the cheaper labor of other countries.^ Henry Towne, past President of the American Society of Mechanical Engineers , wrote in the Foreword to Frederick Winslow Taylor's Shop Management (1911), "We are justly proud of the high wage rates which prevail throughout our country, and jealous of any interference with them by the products of the cheaper labor of other countries.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Henry Towne, past President of the American Society of Mechanical Engineers, wrote in the Foreword to Frederick Winslow Taylor's Shop Management (1911), "We are justly proud of the high wage rates which prevail throughout our country, and jealous of any interference with them by the products of the cheaper labor of other countries.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ Frederick Winslow Taylor, the father of scientific management, introduced what are now called standardization and best practice deployment.

.To maintain this condition, to strengthen our control of home markets, and, above all, to broaden our opportunities in foreign markets where we must compete with the products of other industrial nations, we should welcome and encourage every influence tending to increase the efficiency of our productive processes."^ To maintain this condition, to strengthen our control of home markets, and, above all, to broaden our opportunities in foreign markets where we must compete with the products of other industrial nations, we should welcome and encourage every influence tending to increase the efficiency of our productive processes."
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Widely adopted throughout the world, and gaining ground in less industrialized nations, Lean Manufacturing has become a global standard or set of practices which virtually all companies must adopt in order to be competitive in a global economy.
  • Lean Manufacturing a Brief Introduction 16 January 2010 22:55 UTC www.tpslean.com [Source type: General]

^ This means that IT operations, those responsible for the product and health of the enterprise, must have full visibility and control over their resources - and of course, the technology to do so.
  • Lean Manufacturing White Papers, Software Downloads, Definition and Webcasts - Bitpipe 16 January 2010 22:55 UTC www.bitpipe.com [Source type: General]

Ford starts the ball rolling

.Henry Ford continued this focus on waste while developing his mass assembly manufacturing system.^ Henry Ford continued this focus on waste while developing his mass assembly manufacturing system.
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Lean manufacturing is a system where wastes are defined, identified and removed from the system continuously.
  • What does Lean Manufacturing mean? - Yahoo! Answers 16 January 2010 22:55 UTC answers.yahoo.com [Source type: General]

^ Pull system : a manufacturing planning system based on communication of actual real-time needs from downstream operations ultimately final assembly or the equivalent.
  • Online quality chart generators - Seven basic quality management tools, AM Manufacturing - Lean Manufacturing 2 16 January 2010 22:55 UTC www.qtcharts.com [Source type: FILTERED WITH BAYES]

Charles Buxton Going wrote in 1915:
Ford's success has startled the country, almost the world, financially, industrially, mechanically. It exhibits in higher degree than most persons would have thought possible the seemingly contradictory requirements of true efficiency, which are: constant increase of quality, great increase of pay to the workers, repeated reduction in cost to the consumer. And with these appears, as at once cause and effect, an absolutely incredible enlargement of output reaching something like one hundredfold in less than ten years, and an enormous profit to the manufacturer.[11]
Ford, in My Life and Work (1922),[12] provided a single-paragraph description that encompasses the entire concept of waste:
I believe that the average farmer puts to a really useful purpose only about 5%. of the energy he expends.... Not only is everything done by hand, but seldom is a thought given to a logical arrangement. A farmer doing his chores will walk up and down a rickety ladder a dozen times. He will carry water for years instead of putting in a few lengths of pipe. His whole idea, when there is extra work to do, is to hire extra men. He thinks of putting money into improvements as an expense.... It is waste motion— waste effort— that makes farm prices high and profits low.
.Poor arrangement of the workplace—a major focus of the modern kaizen—and doing a job inefficiently out of habit—are major forms of waste even in modern workplaces.^ Poor arrangement of the workplace-- a major focus of the modern kaizen-- and doing a job inefficiently out of habit-- are major forms of waste even in modern workplaces.
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^ Excess inventory is another form of waste since it is expensive to store, is subject to damage and has a nasty habit of becoming obsolete.
  • Lean manufacturing can save American manufacturing 16 January 2010 22:55 UTC www.reliableplant.com [Source type: FILTERED WITH BAYES]

^ We have used this approach to getting Lean many times, as inventory, in its' many forms, will often point to wastes that exist even in a fairly Lean environment.
  • Lean Manufacturing a Brief Introduction 16 January 2010 22:55 UTC www.tpslean.com [Source type: General]

.Ford also pointed out how easy it was to overlook material waste.^ Ford also pointed out how easy it was to overlook material waste.
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ One of Henry Ford's major success secrets was his ability to see waste that most other people would overlook .
  • Lean Manufacturing and Lean Enterprise 16 January 2010 22:55 UTC www.ct-yankee.com [Source type: FILTERED WITH BAYES]

A former employee, Harry Bennett, wrote:
One day when Mr. Ford and I were together he spotted some rust in the slag that ballasted the right of way of the D. T. & I [railroad]. This slag had been dumped there from our own furnaces. 'You know,' Mr. Ford said to me, 'there's iron in that slag. You make the crane crews who put it out there sort it over, and take it back to the plant.'[13]
.In other words, Ford saw the rust and realized that the steel plant was not recovering all of the iron.^ In other words, Ford saw the rust and realized that the steel plant was not recovering all of the iron.
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^ Hirano, Shingo, Deming and Juran all made great contributions, but the concepts really sprang from Henry Ford and Tayishi Ohno.
  • Operational Excellence | Lean Manufacturing and Pharma: An Interview with Phil Emard | Pharmaceutical Manufacturing 16 January 2010 22:55 UTC www.pharmamanufacturing.com [Source type: General]

^ In other words, the company jumped on the bandwagon of lean without first analyzing what the real problems and constraints were in the factory.
  • Lean Manufacturing, Kaizen, Kanban, Just In Time Articles 16 January 2010 22:55 UTC www.sme.org [Source type: FILTERED WITH BAYES]

Ford's early success, however, was not sustainable. .As James Womack and Daniel Jones pointed out in "Lean Thinking", what Ford accomplished represented the "special case" rather than a robust lean solution.^ You should also check out " Lean Thinking " by James P. Womack.
  • Lean Manufacturing Help, Lean Articles, Principles,Videos, Lean Training 16 January 2010 22:55 UTC www.tpslean.com [Source type: General]

^ Woolley, lean program manager with Intel, has had specialized training and direct application experience in lean manufacturing methods and lean thinking.
  • Lean Manufacturing Courses Precede ISMI Symposium - 2007-08-23 15:07:00 | Semiconductor International 16 January 2010 22:55 UTC www.semiconductor.net [Source type: General]

^ In lean, if something is wrong, you stop the line and fix it now, rather than rework product later.
  • Lean and mean manufacturing - 2006-09-26 06:00:00 | Modern Materials Handling 16 January 2010 22:55 UTC www.mmh.com [Source type: FILTERED WITH BAYES]

[14] .The major challenge that Ford faced was that his methods were built for a steady-state environment, rather than for the dynamic conditions firms increasingly face today.^ They will assess the state of lean as a movement in industry, provide their view on the major issues and challenges facing companies in their lean journeys, and state their analysis and suggestions regarding things to do now and in the future.
  • Lean Manufacturing Conference 16 January 2010 22:55 UTC www.umich.edu [Source type: FILTERED WITH BAYES]

^ SPC techniques are used establish the statistical variability of an output parameter from a machine in steady state conditions.

^ When a business is confronted with a challenge, rather than examining its company-specific needs and roadblocks to find a creative solution, it asks, What would Toyota do?

[15] .Although his rigid, top-down controls made it possible to hold variation in work activities down to very low levels, his approach did not respond well to uncertain, dynamic business conditions; they responded particularly badly to the need for new product innovation.^ It did not cope well with multiple or new products.
  • Lean Manufacturing History 16 January 2010 22:55 UTC www.strategosinc.com [Source type: FILTERED WITH BAYES]

^ Thanks to their proven operational effectiveness, they have emerged as an interlocking group of five basics: - Voice of the Customer for innovation and development - production activities with and without added value - postponement or mass customization and modular thinking - dependent and independent customer demand - the two levels of the supply chain: strategic and operational .
  • Gray Research - Sales and Operations Planning, Manufacturing Education, Lean Manufacturing, Consulting, Software Research 16 January 2010 22:55 UTC www.grayresearch.com [Source type: General]

^ Levels of demand in the Post War economy of Japan were low and the focus of mass production on lowest cost per item via economies of scale had little relevance.
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

.This was made clear by Ford's precipitous decline when the company was forced to finally introduce a follow-on to the Model T (see Lean Dynamics).^ While Bredehoft sees the system as facilitating aspects of lean, he says the company's lean transformation began years ago.
  • Multiple paths to lean - 2002-11-01 07:00:00 | Manufacturing Business Technology 16 January 2010 22:55 UTC www.mbtmag.com [Source type: FILTERED WITH BAYES]

^ The finale of the conference on Thursday morning will pull together leading practitioners and lean advisors to offer practical recommendations for companies on the lean journey.
  • Lean Manufacturing Conference 16 January 2010 22:55 UTC www.umich.edu [Source type: FILTERED WITH BAYES]

^ Under those conditions, it was simply impractical to follow the lead of Henry Ford and make large volumes of black Model Ts.
  • Lean Manufacturing 16 January 2010 22:55 UTC www.bsu.edu [Source type: FILTERED WITH BAYES]

.Design for Manufacture (DFM) also is a Ford concept.^ Design for Manufacture (DFM) also is a Ford concept.
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^ This course is designed for upper and mid-level production managers who want to learn how to successfully implement Lean Manufacturing concepts in their ...
  • The Sixth Sigma - Lean Manufacturing Concepts 16 January 2010 22:55 UTC www.sixthsigma.com [Source type: Academic]

^ A hands-on workshop designed to provide an understanding of the lean concepts fundamental to the creation and improvement of flow in a manufacturing system.
  • Lean Manufacturing Conference 16 January 2010 22:55 UTC www.umich.edu [Source type: FILTERED WITH BAYES]

Ford said in My Life and Work (the same reference describes just in time manufacturing very explicitly):
...entirely useless parts [may be]—a shoe, a dress, a house, a piece of machinery, a railroad, a steamship, an airplane. As we cut out useless parts and simplify necessary ones, we also cut down the cost of making. ... But also it is to be remembered that all the parts are designed so that they can be most easily made.
.This standardization of parts was central to Ford's concept of mass production, and the manufacturing "tolerances", or upper and lower dimensional limits that ensured interchangeability of parts became widely applied across manufacturing.^ Design for Manufacture (DFM) also is a Ford concept.
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Z L Rubber and Plastic Lean Manufacturer Lean manufacturer of rubber and plastic plumbing and water applications including custom and standard rubber parts.
  • Lean Manufacturing Information | Business.com 16 January 2010 22:55 UTC www.business.com [Source type: General]

^ The ultimate competitive goal of the CIF is the ability to produce consumer goods on a custom basis for almost instantaneous delivery at costs lower than those featured by standard mass production firms.
  • GLOSARY: Continuous Improvement, Lean Production, Kaizen, and Total Quality Management terms - and -  Free Ten3 Micro-course KAIZEN and LEAN PRODUCTION 12 September 2009 12:10 UTC www.1000ventures.com [Source type: FILTERED WITH BAYES]

.Decades later, the renowned Japanese quality guru, Genichi Taguchi, demonstrated that this "goal post" method of measuring was inadequate.^ It is key to measure, or estimate, the size of these wastes in order to demonstrate effect of the changes achieved and therefore the movement towards the goal.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
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.He showed that "loss" in capabilities did not begin only after exceeding these tolerances, but increased as described by the Taguchi Loss Function at any condition exceeding the nominal condition.^ These differences show how important it is to use an industrial label printer that's capable of providing this level of performance.

.This became an important part of W. Edwards Deming's quality movement of the 1980s, later helping to develop improved understanding of key areas of focus such as cycle time variation in improving manufacturing quality and efficiencies in aerospace and other industries.^ Key focus areas for leaders are .
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Manufacturers need to focus on the continuous reduction of all cycle times.
  • Lean Manufacturing Basics, Principles and Techniques 16 January 2010 22:55 UTC bbasicsllc.com [Source type: General]

^ Key focus areas for leaders are: .
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
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.While Ford is renowned for his production line it is often not recognized how much effort he put into removing the fitters' work in order to make the production line possible.^ Ford assembly lines were often employed for products and processes that were unsuitable for them.
  • Lean Manufacturing History 16 January 2010 22:55 UTC www.strategosinc.com [Source type: FILTERED WITH BAYES]

^ Whilst Ford is renowned for his production line it is often not recognized how much effort he put into removing the 'fitters' work in order to make the production line possible.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ If you find all this free information useful, just imagine how much your operation will improve when we can work together one on one!
  • Lean Expertise - The opportunity to Learn and Share 16 January 2010 22:55 UTC www.leanexpertise.com [Source type: General]

.Until Ford, a car's components always had to be fitted or reshaped by a skilled engineer at the point of use, so that they would connect properly.^ Until Ford a car's components always had to be 'fitted' or reshaped by a skilled engineer at the point of use so that they would connect properly.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ Most are happy to live in absolute denial and oblivious to the facts until they hit that "pain point of realization".

^ Another approach is to choose connection or power-transport methods that are cheap or that used standardized components that become available in a competitive market.
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.By enforcing very strict specification and quality criteria on component manufacture, he eliminated this work almost entirely, reducing manufacturing effort by between 60-90%.^ By enforcing very strict specification and quality criteria on component manufacture he eliminated this work almost entirely, this reduced manufacturing effort by between 60-90%[7].
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ Applicable in Engineer to Order manufacturing: YES. Involving staff in problem solving, work area layout, set up reduction and design for manufacturing can be very beneficial.

^ The fact that all companies need to reduce operation costs and expenses make up to the companies ever- enduring efforts and initiatives to adopt lean manufacturing principles.

[16] .However, Ford's mass production system failed to incorporate the notion of "pull production" and thus often suffered from over-production.^ However Ford's mass production system failed to incorporate the notion of Pull and thus often suffered from over production.
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^ Taiichi Ohno, Toyota Production System (1988) "In reality, however, such waste [waiting, needless motions] is usually hidden, making it difficult to eliminate.
  • Lean Manufacturing and Lean Enterprise 16 January 2010 22:55 UTC www.ct-yankee.com [Source type: FILTERED WITH BAYES]

^ At Toyota Motor Company, Taichii Ohno and Shigeo Shingo, began to incorporate Ford production and other techniques into an approach called Toyota Production System or Just In Time .
  • Lean Manufacturing History 16 January 2010 22:55 UTC www.strategosinc.com [Source type: FILTERED WITH BAYES]

Toyota develops TPS

.Toyota's development of ideas that later became Lean may have started at the turn of the 20th century with Sakichi Toyoda, in a textile factory with looms that stopped themselves when a thread broke, this became the seed of autonomation and Jidoka.^ Toyota's development of ideas that later became Lean may have started at the turn of the 20 th century with Sakichi Toyoda in their textile business with looms that stopped themselves when a thread broke which became the seed of ‘Autonomation’ and ‘ Jidoka ’.

^ Toyota's development of ideas that later became Lean may have started at the turn of the 20th century with Sakichi Toyoda in their textile business with looms that stopped themselves when a thread broke which became the seed of "Autonomation" and "Jidoka".
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ Toyota's development of ideas that later became Lean may have started at the turn of the 20 th century with Sakichi Toyoda in their textile business with looms that stopped themselves when a thread broke which became the seed of " Autonomation " and " Jidoka ".
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

.Toyota's journey with JIT may have started back in 1934 when it moved from textiles to produce its first car.^ Toyota's journey with JIT may have started back in 1934 when it moved from textiles to produce its first car.
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Toyota's development of ideas that later became Lean may have started at the turn of the 20 th century with Sakichi Toyoda in their textile business with looms that stopped themselves when a thread broke which became the seed of ‘Autonomation’ and ‘ Jidoka ’.

^ Toyota's development of ideas that later became Lean may have started at the turn of the 20 th century with Sakichi Toyoda in their textile business with looms that stopped themselves when a thread broke which became the seed of " Autonomation " and " Jidoka ".
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

.Kiichiro Toyoda, founder of Toyota, directed the engine casting work and discovered many problems in their manufacture.^ Kiichiro Toyoda , founder of Toyota Motor Corp., directed the engine casting work and discovered many problems in their manufacture.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Kiichiro Toyoda, founder of Toyota Motor Corp., directed the engine casting work and discovered many problems in their manufacture.
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^ Applicable in Engineer to Order manufacturing: YES. Involving staff in problem solving, work area layout, set up reduction and design for manufacturing can be very beneficial.

.He decided he must stop the repairing of poor quality by intense study of each stage of the process.^ He decided he must stop the repairing of poor quality by intense study of each stage of the process.
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ AUTO QUALITY MATRIX Management system consisting in showing visually, on the field, the efficiency of every stage of the process, to increase quickly the quality level.
  • LEAN KEY | Kaizen & Lean manufacturing 16 January 2010 22:55 UTC www.lean-key.com [Source type: FILTERED WITH BAYES]

^ This will guide you through the universal stages that ANY change process MUST go through in order to be successful.
  • - Increase Profits | Reduce costs - Lean Manufacturing Tools | Lean Guide | Lean Powerpoint 16 January 2010 22:55 UTC www.beyondlean.info [Source type: General]

.In 1936, when Toyota won its first truck contract with the Japanese government, his processes hit new problems and he developed the "Kaizen" improvement teams.^ In 1936 Toyota won its first truck contract with the Japanese government his processes hit new problems and developed the "Kaizen" improvement teams.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ In 1936 Toyota won its first truck contract with the Japanese government his processes hit new problems and developed the " Kaizen " improvement teams.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ In 1936 Toyota won its first truck contract with the Japanese government his processes hit new problems and developed the ‘Kaizen’ improvement teams.

.Levels of demand in the Post War economy of Japan were low and the focus of mass production on lowest cost per item via economies of scale therefore had little application.^ Levels of demand in the Post War economy of Japan were low and the focus of mass production on lowest cost per item via economies of scale had little relevance.
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^ Therefore it is surprising that lean product development systems have received relatively little attention in the literature.
  • Lean Manufacturing Conference 16 January 2010 22:55 UTC www.umich.edu [Source type: FILTERED WITH BAYES]

^ Consequently such items as lead time, first time through, average cost per unit, sales per employee and on time delivery are measured.
  • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

.Having visited and seen supermarkets in the USA, Taiichi Ohno recognised the scheduling of work should not be driven by sales or production targets but by actual sales.^ Having visited and seen supermarkets in the US Taiichi Ohno recognized the scheduling of work should not be driven by sales or production targets but by actual sales.
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^ Having visited and seen supermarkets in the US Taiichi Ohno recognised the scheduling of work should not be driven by sales or production targets but by actual sales.

^ Taiichi Ohno, Toyota Production System (1988) "In reality, however, such waste [waiting, needless motions] is usually hidden, making it difficult to eliminate.
  • Lean Manufacturing and Lean Enterprise 16 January 2010 22:55 UTC www.ct-yankee.com [Source type: FILTERED WITH BAYES]

.Given the financial situation during this period, over-production had to be avoided and thus the notion of Pull (build to order rather than target driven Push) came to underpin production scheduling.^ Given the financial situation during this period over-production was not an option and thus the notion of Pull (rather than target driven Push) came to underpin production scheduling.
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^ Just-in-time processing: a part moves to a production operation, is processed immediately, and moves immediately to the next operation Short order-to-ship cycles times; small batch production capability that is synchronized to shipping schedules Production is based on orders rather than forecasts; production planning is driven by customer demand or "pull" and not to suit machine loading or inflexible work flows on the shop floor.
  • LEAN PRODUCTION or Lean manufacturing or Toyota Production System (TPS) - Doing More with Less (Free Business e-Coach) 12 September 2009 12:10 UTC www.1000ventures.com [Source type: FILTERED WITH BAYES]

^ In lean, if something is wrong, you stop the line and fix it now, rather than rework product later.
  • Lean and mean manufacturing - 2006-09-26 06:00:00 | Modern Materials Handling 16 January 2010 22:55 UTC www.mmh.com [Source type: FILTERED WITH BAYES]

.It was with Taiichi Ohno at Toyota that these themes came together.^ It was with Taiichi Ohno at Toyota that all these themes came together.
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Taiichi Ohno, Toyota Production System (1988) "In reality, however, such waste [waiting, needless motions] is usually hidden, making it difficult to eliminate.
  • Lean Manufacturing and Lean Enterprise 16 January 2010 22:55 UTC www.ct-yankee.com [Source type: FILTERED WITH BAYES]

^ Taiichi Ohno came up with a system now called the ‘Toyota Production System’ (TPS).
  • Lean Manufacturing 16 January 2010 22:55 UTC www.bsu.edu [Source type: FILTERED WITH BAYES]

.He built on the already existing internal schools of thought and spread their breadth and use into what has now become the Toyota Production System (TPS).^ He built on the already existing internal school of thought and spread its breadth and use into what has now become the Toyota Production System (TPS).
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing 16 January 2010 22:55 UTC www.leandeployment.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Toyota Production System – see " Lean Production " .
  • GLOSARY: Continuous Improvement, Lean Production, Kaizen, and Total Quality Management terms - and -  Free Ten3 Micro-course KAIZEN and LEAN PRODUCTION 12 September 2009 12:10 UTC www.1000ventures.com [Source type: FILTERED WITH BAYES]

^ Most early attempts to emulate Toyota failed because they were not integrated into a complete system and because few understood the underlying principles.
  • Lean Manufacturing History 16 January 2010 22:55 UTC www.strategosinc.com [Source type: FILTERED WITH BAYES]

.It is principally from the TPS, but now including many other sources, that Lean production is developing.^ An overview of Lean Product Development 2007 .
  • Lean Manufacturing - Operations - Management Portal 16 January 2010 22:55 UTC www.themanager.org [Source type: FILTERED WITH BAYES]

^ It is principally from the TPS, but now including many other sources, that Lean production is developing.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ PM Can Lean be applied to product development?
  • Operational Excellence | Lean Manufacturing and Pharma: An Interview with Phil Emard | Pharmaceutical Manufacturing 16 January 2010 22:55 UTC www.pharmamanufacturing.com [Source type: General]

Norman Bodek wrote the following in his foreword to a reprint of Ford's Today and Tomorrow:
I was first introduced to the concepts of just-in-time (JIT) and the Toyota production system in 1980. Subsequently I had the opportunity to witness its actual application at Toyota on one of our numerous Japanese study missions. There I met Mr. Taiichi Ohno, the system's creator. When bombarded with questions from our group on what inspired his thinking, he just laughed and said he learned it all from Henry Ford's book." It is the scale, rigour and continuous learning aspects of the TPS which have made it a core of Lean.

Types of wastes

.While the elimination of waste may seem like a simple and clear subject it is noticeable that waste is often very conservatively identified.^ Based on the premise that every person in the organization is responsible for identifying and eliminating waste.

^ A technique that brings the various tiered levels of the supply chain together to work as a team to identify and eliminate waste in the entire material pipeline.

^ There are seven identified ?forms of waste' within the work environment and systems that lean manufacturing principally aims to alleviate, if not totally eliminate.

This then hugely reduces the potential of such an aim. .The elimination of waste is the goal of Lean, and Toyota defined three broad types of waste: muda, muri and mura; it should be noted that for many Lean implementations this list shrinks to the last waste type only with corresponding benefits decrease.^ In fact, many corporations have only begun to implement lean manufacturing.
  • Lean Manufacturing Information | Business.com 16 January 2010 22:55 UTC www.business.com [Source type: General]

^ Lean is continuous waste elimination.
  • Operational Excellence | Lean Manufacturing and Pharma: An Interview with Phil Emard | Pharmaceutical Manufacturing 16 January 2010 22:55 UTC www.pharmamanufacturing.com [Source type: General]

^ The Toyota Production System defines seven types of waste ("muda"): 1.
  • Lean Manufacturing (Urban Ecology Australia) 16 January 2010 22:55 UTC www.urbanecology.org.au [Source type: FILTERED WITH BAYES]

.To illustrate the state of this thinking Shigeo Shingo observed that only the last turn of a bolt tightens it—the rest is just movement.^ Shigeo Shingo observed that it's only the last turn of a bolt that tightens it - the rest is just movement.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

.This ever finer clarification of waste is key to establishing distinctions between value-adding activity, waste and non-value-adding work.^ Non-value adding work is waste that must be done under the present work conditions.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Analyzing the value stream to identify value added and non-value added activities.
  • SearchManufacturing.com Lean Manufacturing Glossary 16 January 2010 22:55 UTC www.searchmanufacturing.com [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing Glossary - Michigan Manufacturing Technology Center (MMTC) 16 January 2010 22:55 UTC www.mmtc.org [Source type: FILTERED WITH BAYES]

^ Using the 8 wastes as a guide, identify all non-value added activities.

[17] .Non-value adding work is waste that must be done under the present work conditions.^ Non-value adding work is waste that must be done under the present work conditions.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Everything non-value added must be eliminated.
  • Lean Manufacturing (Urban Ecology Australia) 16 January 2010 22:55 UTC www.urbanecology.org.au [Source type: FILTERED WITH BAYES]

^ Reducing Delays in Service Processes with Rapid Setup Job processes that include non-value-added work which increase delays and extend work in progress are common in service functions.
  • Lean, Lean Six Sigma and Lean Manufacturing 16 January 2010 22:55 UTC www.isixsigma.com [Source type: FILTERED WITH BAYES]

.One key is to measure, or estimate, the size of these wastes, in order to demonstrate the effect of the changes achieved and therefore the movement towards the goal.^ It is key to measure, or estimate, the size of these wastes in order to demonstrate effect of the changes achieved and therefore the movement towards the goal.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ However, as long as keeping a project within its original scope is a key project management goal, this measurement will continue to be optimizedat the expense of the overall value delivered by the project.

^ Continuous improvement, customer focus, one-piece flow and waste reduction play key roles in lean manufacturing.
  • Lean Manufacturing: Definition and additional resources from BNET 16 January 2010 22:55 UTC dictionary.bnet.com [Source type: FILTERED WITH BAYES]

.The "flow" (or smoothness) based approach aims to achieve JIT, by removing the variation caused by work scheduling and thereby provide a driver, rationale or target and priorities for implementation, using a variety of techniques.^ The 'flow' (or smoothness) based approach aims to achieve JIT by removing the variation caused by work scheduling and thereby provide a driver, rationale or target and priorities for implementation, using a variety of techniques.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ With a muri or flow based approach .
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Participants will be taught that problems are solved by a synergistic result of a diverse team using a structured approach to describe and define problems, hypothesize and test possible root causes, put solutions to work, and document corrective actions.  Participants will learn: .
  • PMC - Lean Manufacturing Workshops 16 January 2010 22:55 UTC www.pmcorp.com [Source type: Reference]

.The effort to achieve JIT exposes many quality problems that are hidden by buffer stocks; by forcing smooth flow of only value-adding steps, these problems become visible and must be dealt with explicitly.^ The effort to achieve JIT exposes many quality problems that had been hidden by buffer stocks, by forcing smooth flow of only value-adding steps these problems become visible and must be dealt with explicitly.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ The 'flow' (or smoothness) based approach aims to achieve JIT by removing the variation caused by work scheduling and thereby provide a driver, rationale or target and priorities for implementation, using a variety of techniques.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Lean production is an attempt to reduce impediments to the smooth flow of production through various techniques, including continuous improvement in productivity and quality ("kaizen"), "just-in-time" (JIT) inventory systems, and training workers to conduct quality control through Quality Circles.

.Muri is all the unreasonable work that management imposes on workers and machines because of poor organization, such as carrying heavy weights, moving things around, dangerous tasks, even working significantly faster than usual.^ Muri is all the unreasonable work that management imposes on workers because of poor organization, such as carrying heavy weights, moving things around, dangerous tasks, etc.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Demmings basic message was that quality is a management responsibility, and poor quality was almost always the result of systems imposed on workers which thwarted peoples desire to do high quality work.

^ Among the auto parts workers, those in lean companies reported significantly heavier workload, and "too few people", than in traditional companies.

.It is pushing a person or a machine beyond its natural limits.^ It's pushing a person or a machine beyond its natural limits.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

.This may simply be asking a greater level of performance from a process than it can handle without taking shortcuts and informally modifying decision criteria.^ But whether it be at the cell or value stream level, a good touchstone for performance measurement is that no data will be gathered that is not already required to control the production process.
  • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

^ A critical factor in the decision was the level of customization and integration required during the implementation process.
  • Lean Manufacturing | shoplogix Blog 16 January 2010 22:55 UTC www.shoplogixblog.com [Source type: FILTERED WITH BAYES]

^ A High performing team will always achieve greater results than a group of individuals.
  • Lean manufacturing definition | Lean Manufacturing 16 January 2010 22:55 UTC www.beyondlean.com [Source type: FILTERED WITH BAYES]

.Unreasonable work is almost always a cause of multiple variations.^ Unreasonable work is almost always a cause of variation.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Demmings basic message was that quality is a management responsibility, and poor quality was almost always the result of systems imposed on workers which thwarted peoples desire to do high quality work.

.To link these three concepts is simple in TPS and thus Lean.^ Lean: three key concepts .
  • Multiple paths to lean - 2002-11-01 07:00:00 | Manufacturing Business Technology 16 January 2010 22:55 UTC www.mbtmag.com [Source type: FILTERED WITH BAYES]

^ To link these three concepts is straight forward.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Using different lean concepts championed by TPS, businesses in need of a little direction should reevaluate their use of kanban, kaizen, and 5S techniques.

.Firstly, muri focuses on the preparation and planning of the process, or what work can be avoided proactively by design.^ Check: Gather feedback/data from the process to determine if the plan is working.

^ Lean tends to be focused on production because waste and inefficiency is so obvious in the form of inventory, scrap, rework, and work in process.
  • » Implementing Lean Production 12 September 2009 12:10 UTC www.bizmanualz.com [Source type: General]

^ "Muri" is overburden by running a process too hard/fast and must be avoided.
  • IndustryWeek - Leadership in Manufacturing: Lean Webcast Bonus Q&A 16 January 2010 22:55 UTC www.industryweek.com [Source type: FILTERED WITH BAYES]

.Next, mura then focuses on how the work design is implemented and the elimination of fluctuation at the scheduling or operations level, such as quality and volume.^ Mura then focuses on implementation and the elimination of fluctuation at the scheduling or operations level, such as quality and volume.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ By enforcing very strict specification and quality criteria on component manufacture he eliminated this work almost entirely, this reduced manufacturing effort by between 60-90%[7].
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ If you find all this free information useful, just imagine how much your operation will improve when we can work together one on one!
  • Lean Expertise - The opportunity to Learn and Share 16 January 2010 22:55 UTC www.leanexpertise.com [Source type: General]

.Muda is then discovered after the process is in place and is dealt with reactively.^ The third — Muda — is discovered after the process is in place and is dealt with reactively.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ The third — Muda — is discovered after the process is in place and is dealt with reactively.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

.It is seen through variation in output.^ It is seen through variation in output.
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  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

.It is the role of management to examine the muda, in the processes and eliminate the deeper causes by considering the connections to the muri and mura of the system.^ It is the role of management to examine the Muda, or waste, in the processes and eliminate the deeper causes by considering the connections to Muri and Mura of the system.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ In the words of Taiichi Ohno "eliminate muda, mura, muri completely".
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Even worse, they put Muda back that managers and operations teams have already eliminated once.
  • Lean Manufacturing Consulting - ProModel 16 January 2010 22:55 UTC webdev1.promodel.com [Source type: General]

.The muda and mura inconsistencies must be fed back to the muri, or planning, stage for the next project.^ The Muda – waste – and Mura – inconsistencies – must be fed back to the Muri, or planning, stage for the next project.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ The Muda – waste – and Mura – inconsistencies – must be fed back to the Muri, or planning, stage for the next project.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ Take a careful look at your Muri and your Mura as you start to tackle your Muda.” .
  • Lean Manufacturing Consulting - ProModel 16 January 2010 22:55 UTC webdev1.promodel.com [Source type: General]

.A typical example of the interplay of these wastes is the corporate behaviour of "making the numbers" as the end of a reporting period approaches.^ A typical example of the interplay of these wastes is the corporate behavior of "making the numbers" as the end of a reporting period approaches.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ A typical example of the interplay of these wastes is the corporate behaviour of "making the numbers" as the end of a reporting period approaches.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ Lean Management Accounting is one of a number of elements making up a lean accounting approach within a manufacturing company.
  • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

.Demand is raised in order to 'make plan', increasing (mura), when the "numbers" are low which causes production to try to squeeze extra capacity from the process which causes routines and standards to be modified or stretched.^ Comparing products and/or processes to a standard in order to evaluate and improve performance.
  • Lean Manufacturing Glossary - Michigan Manufacturing Technology Center (MMTC) 16 January 2010 22:55 UTC www.mmtc.org [Source type: FILTERED WITH BAYES]

^ Demand surges (mura) where the "numbers" are low which causes production to try to squeeze extra capacity from the process which causes routines and standards to be modified or stretched.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ For although the effects can not be seen in the aggregate, lean improvements cause a decided change in how the resources are used—shifting from non productive uses such as change over, rework, making excess to making them available for increasing the business or for elimination.
  • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

.This stretch and improvisation leads to muri-style waste which leads to downtime, mistakes and backflows and waiting, thus the muda of waiting, correction and movement.^ This stretch and improvisation leads to muri style waste which leads to downtime, mistakes and backflows and waiting, thus the muda of waiting, correction and movement.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Elimination of waste is the goal of Lean, Toyota defined three types of waste: muda or nonvalue-added work, muri or overburden and mura or unevenness.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ The Muda – waste – and Mura – inconsistencies – must be fed back to the Muri, or planning, stage for the next project.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

The original seven muda are:
  • Transportation (moving products that is not actually required to perform the processing)
  • Inventory (all components, work in process and finished product not being processed)
  • Motion (people or equipment moving or walking more than is required to perform the processing)
  • Waiting (waiting for the next production step)
  • Overproduction (production ahead of demand)
  • Over Processing (due to poor tool or product design creating activity)
  • Defects (the effort involved in inspecting for and fixing defects)[18]
.Later an eighth waste was defined by Womack et al.^ Post Date: May 11, 2006 5:49 AM I'm not sure Berggren even read the Womack et al books.
  • Lean Manufacturing Blog, Kaizen Articles and Advice | Gemba Panta Rei 12 September 2009 12:10 UTC www.gembapantarei.com [Source type: FILTERED WITH BAYES]

.(2003); it was described as manufacturing goods or services that do not meet customer demand or specifications.^ When applied 'right', SMED can make the difference between profit and loss, and being able to meet the changing demands of your customer.
  • KAIZEN Institute Lean Advisors - Manufacturing - KAIZEN Lean Training, KAIZEN Lean Service, KAIZEN Lean Manufacturing 16 January 2010 22:55 UTC www.leanadvisors.com [Source type: FILTERED WITH BAYES]

^ June 2009 - (Free Research) With compliant manufacturing operations, you can deliver quality products to customers consistently and meet good manufacturing practices regulations at the lowest cost possible - all key to leading the competition.
  • Lean Manufacturing Goals - Manufacturing Business Technology Results for Lean Manufacturing Goals 16 January 2010 22:55 UTC researchlibrary.mbtmag.com [Source type: Academic]

^ You have a greater chance to meet your customer demands when your efforts are focused on only critical items.

.Many others have added the "waste of unused human talent" to the original seven wastes.^ The original seven muda 'deadly wastes' are: .
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ Many people refer to Shingo’s Seven Wastes: waste of processing, waste of waiting, waste from defects, waste of motion, waste from inventories, waste from over-production, and waste of transportation.
  • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

^ It is renowned for its focus on reduction of the original Toyota 'seven wastes' in order to improve overall customer value.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

.These wastes were not originally a part of the seven deadly wastes defined by Taiichi Ohno in TPS, but were found to be useful additions in practice.^ The original seven muda 'deadly wastes' are: .
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Looking at ways to eliminate waste using the same essential techniques to enhance flow that Taiichi Ohno invented fifty years ago.
  • KAIZEN Institute Lean Advisors - Manufacturing - KAIZEN Lean Training, KAIZEN Lean Service, KAIZEN Lean Manufacturing 16 January 2010 22:55 UTC www.leanadvisors.com [Source type: FILTERED WITH BAYES]

^ Taiichi Ohno, Toyota Production System (1988) "In reality, however, such waste [waiting, needless motions] is usually hidden, making it difficult to eliminate.
  • Lean Manufacturing and Lean Enterprise 16 January 2010 22:55 UTC www.ct-yankee.com [Source type: FILTERED WITH BAYES]

For a complete listing of the "old" and "new" wastes see Bicheno and Holweg (2009)[19]
.Some of these definitions may seem rather idealistic, but this tough definition is seen as important and they drove the success of TPS. The clear identification of non-value-adding work, as distinct from wasted work, is critical to identifying the assumptions behind the current work process and to challenging them in due course.^ Some of these definitions may seem rather 'idealist' but this tough definition is seen as important.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Non-value adding work is waste that must be done under the present work conditions.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ It is really a Value Added course which could help to improve in any bottleneck in working process.
  • Six Sigma Green Belt Certification,Six Sigma Black Belt Certification,Six Sigma Yellow Belt Certification,Six Sigma Certification India 9 October 2009 8:58 UTC www.benchmarksixsigma.com [Source type: FILTERED WITH BAYES]

[20] .Breakthroughs in SMED and other process changing techniques rely upon clear identification of where untapped opportunities may lie if the processing assumptions are challenged.^ Breakthroughs in SMED and other process changing techniques rely upon clear identification of where untapped opportunities may lie if the processing assumptions are challenged.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ These concepts of flexibility and change are principally required to allow production leveling, using tools like SMED , but have their analogues in other processes such as R&D. The flexibility and ability to change are not open-ended, and therefore often expensive, capability requirements.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ These concepts of flexibility and change are principally required to allow production leveling, using tools like SMED, but have their analogues in other processes such as R&D. The flexibility and ability to change are not open-ended, and therefore often expensive, capability requirements.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

Lean implementation develops from TPS

.The discipline required to implement Lean and the disciplines it seems to require are so often counter-cultural that they have made successful implementation of Lean a major challenge.^ Lean Implementation Challenges • Creating corporate cultural change and getting “buy-in” required for success • Quantitatively prioritizing Lean projects • Understanding ROI of the entire initiative • Accurately quantifying the systemic impact of local Kaizen on the Value Stream • Sustaining improvements after Kaizen .
  • Lean Manufacturing Consulting - ProModel 16 January 2010 22:55 UTC webdev1.promodel.com [Source type: General]

^ It is very easy to implement “display Lean” with all of the surface similarities but not the supporting human resource development and management problem solving disciplines built in.
  • Lean Manufacturing Blog, Kaizen Articles and Advice | Gemba Panta Rei 12 September 2009 12:10 UTC www.gembapantarei.com [Source type: FILTERED WITH BAYES]

^ Leaders often believe they don’t have time to commit to active participation, that it’s sufficient to proclaim the importance of Lean.

.Some[21] would say that it was a major challenge in its manufacturing 'heartland' as well.^ And, this, as lean manufacturing says (and any businessperson would say) is major waste.

^ In some industries, piled up inventories are positive, but in almost all, or the majority of manufacturing firms, inventories should be kept controlled because prices of the goods are affected by piled up inventories.

.Implementations under the Lean label are numerous and whether they are Lean and whether any success or failure can be laid at Lean's door is often debatable.^ As one of the early and most successful adopters of lean management principals, Wiremold became a popular tour destination for American executives and managers seeking to implement lean principles.
  • Lean Management Accounting Workshop Resolves Conflicts Between Lean Thinking and Traditional Accounting. | Management > Lean Manufacturing from AllBusiness.com 9 October 2009 8:58 UTC www.allbusiness.com [Source type: News]

^ However, the success of lean manufacturing adoption and implementation depends and principally relies on the effective and religious implementation of the simple and easy to do strategic principles.

^ A value added, learning experience on "how to" design, implement and deploy a lean manufacturing methodology for personal and company success.
  • Lean Manufacturing Basics, Principles and Techniques 16 January 2010 22:55 UTC bbasicsllc.com [Source type: General]

.Individual examples of success and failure exist in almost all spheres of business and activity and therefore cannot be taken as indications of whether Lean is particularly applicable to a specific sector of activity.^ Almost all auto parts makers have at least some successes to show with lean.
  • IndustryWeek - Leadership in Manufacturing: Lean Webcast Bonus Q&A 16 January 2010 22:55 UTC www.industryweek.com [Source type: FILTERED WITH BAYES]

^ Companies from all walks of business are dedicated to lean - to the point that they have in house experts ready and willing to spread the word.

^ The lesson we have been learning all along: No lean process, be it TPM or Six Sigma -- worker based or data driven -- is a panacea for any business.

It seems clear from the "successes" that no sector is immune from beneficial possibility.
.
Lean is about more than just cutting costs in the factory.
^ Lean is about more than just cutting costs in the factory.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Striving to improve competitiveness by providing customers faster and better products/services will accomplish more than worrying about the next crisis.
  • KAIZEN Institute Lean Advisors - Manufacturing - KAIZEN Lean Training, KAIZEN Lean Service, KAIZEN Lean Manufacturing 16 January 2010 22:55 UTC www.leanadvisors.com [Source type: FILTERED WITH BAYES]

^ Clearly, the concepts driving Lean can be and are being adopted by more drug companies, and not just for manufacturing.
  • Operational Excellence | Lean Manufacturing and Pharma: An Interview with Phil Emard | Pharmaceutical Manufacturing 16 January 2010 22:55 UTC www.pharmamanufacturing.com [Source type: General]

[22] .One crucial insight is that most costs are assigned when a product is designed, (see Genichi Taguchi).^ One crucial insight is that most costs are assigned when a product is designed, (see Genichi Taguchi ).
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ One crucial insight is that most costs are assigned when a product is designed, (see Genichi Taguchi).
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ One of Henry Ford's major success secrets was his ability to see waste that most other people would overlook .
  • Lean Manufacturing and Lean Enterprise 16 January 2010 22:55 UTC www.ct-yankee.com [Source type: FILTERED WITH BAYES]

.Often an engineer will specify familiar, safe materials and processes rather than inexpensive, efficient ones.^ Often an engineer will specify familiar, safe materials and processes rather than inexpensive, efficient ones.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ This approach created distinct departmental silos in many operations which are still in place today where one department may optimize its efficiency at the cost of the overall process.
  • Operational Excellence | Lean Manufacturing and Pharma: An Interview with Phil Emard | Pharmaceutical Manufacturing 16 January 2010 22:55 UTC www.pharmamanufacturing.com [Source type: General]

^ Defect prevention rather than inspection and rework by building quality in the process and implementing real time quality feedback procedures.
  • LEAN PRODUCTION or Lean manufacturing or Toyota Production System (TPS) - Doing More with Less (Free Business e-Coach) 12 September 2009 12:10 UTC www.1000ventures.com [Source type: FILTERED WITH BAYES]

.This reduces project risk, that is, the cost to the engineer, while increasing financial risks, and decreasing profits.^ This reduces project risk, that is, the cost to the engineer, while increasing financial risks, and decreasing profits.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ BASICS for increasing speed, improving quality and reducing non-value-added costs...
  • Lean Manufacturing Basics, Principles and Techniques 16 January 2010 22:55 UTC bbasicsllc.com [Source type: General]

^ If your improvements don’t increase value by reducing costs, lead time, and quality issues, the customer will end up paying more for your products.

.Good organizations develop and review checklists to review product designs.^ Good organizations develop and review checklists to review product designs.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Recording, managing positions of components to the whole system in design, development, production, support of a product throughout its life cycle.
  • KAIZEN Institute Lean Advisors - Manufacturing - KAIZEN Lean Training, KAIZEN Lean Service, KAIZEN Lean Manufacturing 16 January 2010 22:55 UTC www.leanadvisors.com [Source type: FILTERED WITH BAYES]

^ Improsys " Improsys is a business improvement solutions organization with focus in the area of systems design ,systems development & systems implementation.
  • Lean Manufacturing - Training Seminars, Resources and Workshops 16 January 2010 22:55 UTC www.training-classes.com [Source type: General]

.Companies must often look beyond the shop-floor to find opportunities for improving overall company cost and performance.^ Companies must often look beyond the shop floor to find opportunities for improving overall company cost and performance.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ Companies must often look beyond the shop-floor to find opportunities for improving overall company cost and performance.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Features and characteristics provide the direct link from a top-down target cost to the day-to-day activities on the shop floor.
  • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

.At the system engineering level, requirements are reviewed with marketing and customer representatives to eliminate those requirements which are costly.^ At the system engineering level, requirements are reviewed with marketing and customer representatives to eliminate costly requirements.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ This will require a good understanding of waste (and value) from the customer’s perspective and then we will need to be relentlessly pursuing systematic waste elimination on a daily basis.

^ Lean management accounting eliminates these requirements so that the accounting systems reflect the simplification and waste reduction efforts required in a lean environment.
  • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

.Shared modules may be developed, such as multipurpose power supplies or shared mechanical components or fasteners.^ Shared modules may be developed, such as multipurpose power-supplies or shared mechanical components or fasteners.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ Xantrex: Manufactures a family of programmable DC power supplies for a variety of applications in industrial, educational, research and development environments.
  • KAIZEN Institute Lean Advisors - Manufacturing - KAIZEN Lean Training, KAIZEN Lean Service, KAIZEN Lean Manufacturing 16 January 2010 22:55 UTC www.leanadvisors.com [Source type: FILTERED WITH BAYES]

.Requirements are assigned to the cheapest discipline.^ Requirements are assigned to the cheapest discipline.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

.For example, adjustments may be moved into software, and measurements away from a mechanical solution to an electronic solution.^ For example, adjustments may be moved into software, and measurements away from a mechanical solution to an electronic solution.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

.Another approach is to choose connection or power-transport methods that are cheap or that used standardized components that become available in a competitive market.^ Another approach is to choose connection or power-transport methods that are cheap or that used standardized components that become available in a competitive market.
  • Lean Manufacturing - Worldwide Quality Network, Inc. 16 January 2010 22:55 UTC www.wqntoday.com [Source type: FILTERED WITH BAYES]

^ The learning based on positive philosophical thinking approach coupled with powerful tried and tested scientific tools that can be used not only at work but also in one's personal life.
  • Six Sigma Green Belt Certification,Six Sigma Black Belt Certification,Six Sigma Yellow Belt Certification,Six Sigma Certification India 9 October 2009 8:58 UTC www.benchmarksixsigma.com [Source type: FILTERED WITH BAYES]

^ Standardization and Continuous Improvement (kaizen) To standardize a method is to choose out of many methods the best one, and use it.
  • Lean Manufacturing and Lean Enterprise 16 January 2010 22:55 UTC www.ct-yankee.com [Source type: FILTERED WITH BAYES]

An example program

In summary, an example of a lean implementation program could be:
With a tools-based approach
    .
  • Senior management to agree and discuss their lean vision
  • Management brainstorm to identify project leader and set objectives
  • Communicate plan and vision to the workforce
  • Ask for volunteers to form the Lean Implementation team (5-7 works best, all from different departments)
  • Appoint members of the Lean Manufacturing Implementation Team
  • Train the Implementation Team in the various lean tools - make a point of trying to visit other non competing businesses which have implemented lean
  • Select a Pilot Project to implement – 5S is a good place to start
  • Run the pilot for 2–3 months - evaluate, review and learn from your mistakes
  • Roll out pilot to other factory areas
  • Evaluate results, encourage feedback
  • Stabilize the positive results by teaching supervisors how to train the new standards you've developed with TWI methodology (Training Within Industry)
  • Once you are satisfied that you have a habitual program, consider introducing the next lean tool.^ Flow, like its other lean manufacturing siblings, differs ...

    ^ Manufacturers: try out our new Lean Assessment Tool .
    • Business Lean 16 January 2010 22:55 UTC blog.kanban.com [Source type: General]

    ^ Lean applies to non manufacturing settings just as strongly as it applies to manufacturing.
    • Six Sigma Green Belt Certification,Six Sigma Black Belt Certification,Six Sigma Yellow Belt Certification,Six Sigma Certification India 9 October 2009 8:58 UTC www.benchmarksixsigma.com [Source type: FILTERED WITH BAYES]

    Select the one which will give you the biggest return for your business.
With a muri or flow based approach (as used in the TPS with suppliers[23]).
    .
  • Sort out as many of the visible quality problems as you can, as well as downtime and other instability problems, and get the internal scrap acknowledged and its management started.
  • Make the flow of parts through the system or process as continuous as possible using workcells and market locations where necessary and avoiding variations in the operators work cycle
  • Introduce standard work and stabilise the work pace through the system
  • Start pulling work through the system, look at the production scheduling and move towards daily orders with kanban cards
  • Even out the production flow by reducing batch sizes, increase delivery frequency internally and if possible externally, level internal demand
  • Improve exposed quality issues using the tools
  • Remove some people (or increase quotas) and go through this work again (the Oh No !!^ Many companies introduce kanban production control but their accounting systems continue to require the tracking of financial information through production work orders and other documents.
    • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

    ^ Just-in-Time/continuous-flow production techniques to reduce lot sizes, reduce setup time, drastically cut work-in-process inventory, improve throughput, and reduce manufacturing cycle time.
    • Lean Manufacturing (Urban Ecology Australia) 16 January 2010 22:55 UTC www.urbanecology.org.au [Source type: FILTERED WITH BAYES]

    ^ This has reduced replenishment downtime significantly – helping to increase production through this machine by 25%.
    • Lean Manufacturing | shoplogix Blog 16 January 2010 22:55 UTC www.shoplogixblog.com [Source type: FILTERED WITH BAYES]

    moment)

Lean leadership

.The role of the leaders within the organization is the fundamental element of sustaining the progress of lean thinking.^ PERFECTION within lean thinking has two elements.
  • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

^ Leadership Move 2: Build Tension, Not Stress A Lean leader needs to be the source of energy that compels the organization toward action.

^ Lean Management Accounting is one of a number of elements making up a lean accounting approach within a manufacturing company.
  • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

.Experienced kaizen members at Toyota, for example, often bring up the concepts of Senpai, Kohai, and Sensei, because they strongly feel that transferring of Toyota culture down and across Toyota can only happen when more experienced Toyota Sensei continuously coach and guide the less experienced lean champions.^ Using different lean concepts championed by TPS, businesses in need of a little direction should reevaluate their use of kanban, kaizen, and 5S techniques.

^ Quality Analyst, Accenture This course is not only for the quality department but for all levels of management, it is necessary for every one to understand the concepts to do their respective jobs more efficiently.
  • Six Sigma Green Belt Certification,Six Sigma Black Belt Certification,Six Sigma Yellow Belt Certification,Six Sigma Certification India 9 October 2009 8:58 UTC www.benchmarksixsigma.com [Source type: FILTERED WITH BAYES]

^ It is a "do it now" approach to continuous, incremental improvement of an activity to create more value with less muda.
  • Lean manufacturing definition | Lean Manufacturing 16 January 2010 22:55 UTC www.beyondlean.com [Source type: FILTERED WITH BAYES]

.Unfortunately, most lean practitioners in North America focus on the tools and methodologies of lean, versus the philosophy and culture of lean.^ Tools on their own will not translate into a sustainable Lean culture.

^ Lean manufacturing is a management philosophy that concentrates on eliminating wastes and dividing the resources of the company into departments and business projects that requires the most immediate attention.

^ Why is it that companies usually focus only on the Lean tools, rather than on the thinking that is required to correctly deploy the tools?

.Some exceptions include Shingijitsu Consulting out of Japan, which is made up of ex-Toyota managers, and Lean Sensei International based in North America, which coaches lean through Toyota-style cultural experience.^ Some exceptions include Shingijitsu Consulting out of Japan, which is made up of ex-Toyota managers, and Lean Sensei International based in North America, which coaches lean through Toyota-style cultural experience.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ Experienced kaizen members at Toyota, for example, often bring up the concept of "Senpai, Kohai," and "Sensei," because they strongly feel that transferring of Toyota culture down and across the Toyota can only happen when more experienced Toyota Sensei continuously coaches and guides the less experienced lean champions.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ To achieve these three at once there is a belief held by some that Toyota's mentoring process (loosely called Senpai and Kohai relationship), so strongly supported in Japan, is one of the best ways to foster Lean Thinking up and down the organizational structure.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

.One of the dislocative effects of Lean is in the area of key performance indicators (KPI).^ Definition and implementation of Key Performance Indicators (KPI).
  • Lean Manufacturing - Training Seminars, Resources and Workshops 16 January 2010 22:55 UTC www.training-classes.com [Source type: General]

^ Metric – A measure that is considered to be a key indicator of performance.

^ Lean manufacturing trainings are somehow viewed by modern companies as one of the business aspects and areas where investments should really be poured in.

The KPIs by which a plant/facility are judged will often be driving behaviour, because the KPIs themselves assume a particular approach to the work being done. .This can be an issue where, for example a truly Lean, Fixed Repeating Schedule (FRS) and JIT approach is adopted, because these KPIs will no longer reflect performance, as the assumptions on which they are based become invalid.^ Of all the issues involved, the people and cultural change issues are, and will continue to be, the major negatives involved with implementing a lean, cellular manufacturing approach.
  • Lean Manufacturing (Urban Ecology Australia) 16 January 2010 22:55 UTC www.urbanecology.org.au [Source type: FILTERED WITH BAYES]

^ Business Goal: Ryerson adopted a Six Sigma approach to drive a measurement-based strategy that focused on process improvement.
  • Lean Manufacturing | shoplogix Blog 16 January 2010 22:55 UTC www.shoplogixblog.com [Source type: FILTERED WITH BAYES]

^ A better approach to these problems is to revamp the bonuses so they are rolling averages rather that don't encourage big batches of orders.
  • IndustryWeek - Leadership in Manufacturing: Lean Webcast Bonus Q&A 16 January 2010 22:55 UTC www.industryweek.com [Source type: FILTERED WITH BAYES]

.It is a key leadership challenge to manage the impact of this KPI chaos within the organization.^ Management buy-in must turn into leadership commitment, or the organization will never reach full potential.

^ However, as long as keeping a project within its original scope is a key project management goal, this measurement will continue to be optimizedat the expense of the overall value delivered by the project.

^ Leadership Move 1: Leaders Must Be Teachers In a Lean organization, learning is critical, and line management’s direct responsibility.

A set of performance metrics which is considered to fit well in a Lean environment is Overall Equipment Effectiveness, or OEE.
.Similarly, commonly used accounting systems developed to support mass production are no longer appropriate for companies pursuing Lean.^ PM Can Lean be applied to product development?
  • Operational Excellence | Lean Manufacturing and Pharma: An Interview with Phil Emard | Pharmaceutical Manufacturing 16 January 2010 22:55 UTC www.pharmamanufacturing.com [Source type: General]

^ Recording, managing positions of components to the whole system in design, development, production, support of a product throughout its life cycle.
  • KAIZEN Institute Lean Advisors - Manufacturing - KAIZEN Lean Training, KAIZEN Lean Service, KAIZEN Lean Manufacturing 16 January 2010 22:55 UTC www.leanadvisors.com [Source type: FILTERED WITH BAYES]

^ Lean manufacturing techniques flexes this attribute by effectively allowing employees to get used to a system and then do it frequently for more efficiency.

.Lean Accounting provides truly Lean approaches to business management and financial reporting.^ The Elements of Lean Management Accounting We will look briefly at each of the elements of this lean management accounting approach.
  • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

^ Lean processing, long a staple in manufacturing, provides this opportunity for increasing efficiency within financial services.
  • Lean Production IT Reports, Webcasts and White Papers 12 September 2009 12:10 UTC cramsession.bitpipe.com [Source type: General]

^ This paper has presented the basic elements of an approach that supports the goals of lean manufacturing and that provides information to maximize the financial benefits from lean.
  • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

.After formulating the guiding principles of its lean manufacturing approach in the Toyota Production System (TPS) Toyota formalized in 2001 the basis of its lean management: the key managerial values and attitudes needed to sustain continuous improvement in the long run.^ With lean manufacturing, there is no 'this will have to do' attitude.

^ The lean approach is not restricted to manufacturing.
  • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

^ Many of the Lean tools have originated in the Toyota Production System.
  • KAIZEN Institute Lean Advisors - Manufacturing - KAIZEN Lean Training, KAIZEN Lean Service, KAIZEN Lean Manufacturing 16 January 2010 22:55 UTC www.leanadvisors.com [Source type: FILTERED WITH BAYES]

.These core management principles are articulated around the twin pillars of Continuous Improvement (relentless elimination of waste) and Respect for People (engagement in long term relationships based on continuous improvement and mutual trust).^ The advantages in terms of waste to profit relationships .

^ We savagely eliminate waste from these processes.
  • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

^ Lean is continuous waste elimination.
  • Operational Excellence | Lean Manufacturing and Pharma: An Interview with Phil Emard | Pharmaceutical Manufacturing 16 January 2010 22:55 UTC www.pharmamanufacturing.com [Source type: General]

This formalization stems from problem solving. .As Toyota expanded beyond its home base for the past 20 years, it hit the same problems in getting TPS properly applied that other western companies have had in copying TPS. Like any other problem, it has been working on trying a series of countermeasures to solve this particular concern.^ In 1936 Toyota won its first truck contract with the Japanese government his processes hit new problems and developed the "Kaizen" improvement teams.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ Kiichiro Toyoda, founder of Toyota Motor Corp., directed the engine casting work and discovered many problems in their manufacture.
  • Lean Velocity: Lean Manufacturing 16 January 2010 22:55 UTC www.leanvelocity.ca [Source type: FILTERED WITH BAYES]

^ This is achieved by getting each person to take initiative to actually solve problems that improve his or her job, by placing individual responsibility at the lowest possible level where the work is actually done.

.These countermeasures have focused on culture: how people behave, which is the most difficult challenge of all.^ Of all the issues involved, the people and cultural change issues are, and will continue to be, the major negatives involved with implementing a lean, cellular manufacturing approach.
  • Lean Manufacturing (Urban Ecology Australia) 16 January 2010 22:55 UTC www.urbanecology.org.au [Source type: FILTERED WITH BAYES]

^ Set the example of how we want our team leaders to behave with their people.

^ All too often, these contracts were focused on keeping the companies from cheating each other.

.Without the proper behavioral principles and values, TPS can be totally misapplied and fail to deliver results.^ This principle is about working towards a process that delivers “value” with the most effective use of our resources.

As one sensei said, one can create a Buddha image and forget to inject soul in it. As with TPS, the values had originally been passed down in a master-disciple manner, from boss to subordinate, without any written statement on the way. And just as with TPS, it was internally argued that formalizing the values would stifle them and lead to further misunderstanding. .But as Toyota veterans eventually wrote down the basic principles of TPS, Toyota set to put the Toyota Way into writing to educate new joiners.^ When the principles of nemawashi are put into effect first, people have the time to adjust opinions beforehand without wasting time.
  • Lean manufacturing definition | Lean Manufacturing 16 January 2010 22:55 UTC www.beyondlean.com [Source type: FILTERED WITH BAYES]

^ A basic principle of Lean Manufacturing is to drive decisions down to the lowest possible level, providing both the tools and the authority for people on the floor to make decisions.

^ Perfection - One of the principles of lean manufacturing takes into mind that there are lots of ways of using company assets efficiently.

[24]
Continuous Improvement breaks down into three basic principles:
.
  1. Challenge : Having a long term vision of the challenges one needs to face in order to realize one's ambition (what we need to learn rather than what we want to do‹and then having the spirit to face that challenge).^ One of the problems with heavyweight intermediate documentation is that it attempts to make all of the decisions for developers, rather than giving them a set of guidelines.

    ^ One learning challenge of a Six Sigma deployment involves training the Six Sigma project teams.

    ^ He taught that teamwork and long term, trust-based relationships with suppliers were far better than adversarial relationships.

    To do so, we have to challenge ourselves every day to see if we are achieving our goals.
  2. Kaizen : Good enough never is, no process can ever be thought perfect, so operations must be improved continuously, striving for innovation and evolution.
  3. Genchi Genbutsu : Going to the source to see the facts for oneself and make the right decisions, create consensus, and make sure goals are attained at the best possible speed.
Respect For People is less known outside of Toyota, and essentially involves two defining principles:
.
  1. Respect Taking every stakeholders' problems seriously, and making every effort to build mutual trust.^ Make sure we take care of problems straight away.

    Taking responsibility for other people reaching their objectives. Thought provoking, I find. .As a manager, I must take responsibility for my subordinates reaching the target I set for them.
  2. Teamwork : This is about developing individuals through team problem-solving.^ One of the problems with heavyweight intermediate documentation is that it attempts to make all of the decisions for developers, rather than giving them a set of guidelines.

    ^ Our visibility shows that we care about how things are going, and want to support the teams to set targets and improve performance.

    ^ It uses a variety of quality tools such as QFD, Taguchi methods, SPC, corrective-action response teams, cause-and-effect analysis, problem-solving methodologies, and fail-safing.
    • Lean manufacturing definition | Lean Manufacturing 16 January 2010 22:55 UTC www.beyondlean.com [Source type: FILTERED WITH BAYES]

    .The idea is to develop and engage people through their contribution to team performance.^ This was accomplished through formation of teams that were trained in work measurement and improvement techniques and expected to develop and continually improve their own work standards and practices.

    Shop floor teams, the whole site as team, and team Toyota at the outset.

Differences from TPS

.Whilst Lean is seen by many as a generalization of the Toyota Production System into other industries and contexts there are some acknowledged differences that seem to have developed in implementation.^ There are differences in end product, in production, company size, equipment, building makeup, company hierarchy and culture, needs, etc.

^ I have seen several instances in repetitive production environments where a simple Kanban materials-control system would suffice, while reducing inventories and improving operations dramatically.
  • Lean Manufacturing (Urban Ecology Australia) 16 January 2010 22:55 UTC www.urbanecology.org.au [Source type: FILTERED WITH BAYES]

^ Still, there are some other institutes that combine the black belt and green belt Six Sigma Training into what is known as the 2+2 format.

.
  1. Seeking profit is a relentless focus for Toyota exemplified by the profit maximization principle (Price – Cost = Profit) and the need, therefore, to practice systematic cost reduction (through TPS or otherwise) in order to realize benefit.^ The 7 wastes will be useful, however our focus on waste is not complete unless our processes and practices systematically address waste on a daily basis.

    ^ Through the introduction of mistake proofing principles to financial measurements all staff can be guided to the correct decisions that ensure optimal profitability.
    • Lean Manufacturing | shoplogix Blog 16 January 2010 22:55 UTC www.shoplogixblog.com [Source type: FILTERED WITH BAYES]

    ^ One of the greatest benefits is that managers have the ability to see if the plant is profitable RIGHT NOW, in real-time not after it is too late.
    • Lean Manufacturing | shoplogix Blog 16 January 2010 22:55 UTC www.shoplogixblog.com [Source type: FILTERED WITH BAYES]

    .Lean implementations can tend to de-emphasise this key measure and thus become fixated with the implementation of improvement concepts of “flow” or “pull”.^ This course is designed for upper and mid-level production managers who want to learn how to successfully implement Lean Manufacturing concepts in their ...
    • The Sixth Sigma - Lean Manufacturing Concepts 16 January 2010 22:55 UTC www.sixthsigma.com [Source type: Academic]

    ^ The five principles of lean thinking presented by Womack are: - Value - Value stream - Flow - Pull - Perfection .
    • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

    ^ I am now becoming involved in lean implementation projects -- developing the training, project plans, etc.
    • IndustryWeek - Leadership in Manufacturing: Lean Webcast Bonus Q&A 16 January 2010 22:55 UTC www.industryweek.com [Source type: FILTERED WITH BAYES]

    .However, the emergence of the "value curve analysis" promises to directly tie lean improvements to bottom-line performance measuments.^ This typically occurs after the first one or two cell implementations, when management notices there were no beneficial improvements to the plant's bottom line performance.
    • Lean Manufacturing (Urban Ecology Australia) 16 January 2010 22:55 UTC www.urbanecology.org.au [Source type: FILTERED WITH BAYES]

    ^ A lean manufacturing company is concerned about controlling the value streams through day-to-day visual control and week-by-week continuous improvement.
    • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

    ^ Based on these measures the continuous improvement team can isolate the constraints to achieving the goals and focus on right problems to improve lean performance.
    • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

    20
  2. .
  3. Tool orientation is a tendency in many programs to elevate mere tools (standardized work, value stream mapping, visual control, etc.^ Information about activities is derived from the information about each manufacturing process that is included on "data boxes" on the value stream maps.
    • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

    ^ A lean manufacturing company is concerned about controlling the value streams through day-to-day visual control and week-by-week continuous improvement.
    • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

    ^ The measurement of each value stream is the starting point for control and continuous improvement.
    • Lean Management Accounting 9 October 2009 8:58 UTC www.maskell.com [Source type: FILTERED WITH BAYES]

    ) to an unhealthy status beyond their pragmatic intent. .The tools are just different ways to work around certain types of problems but they do not solve them for you or always highlight the underlying cause of many types of problems.^ So…it all comes together as an analytic process but you will devote the most work to your biggest problems.
    • IndustryWeek - Leadership in Manufacturing: Lean Webcast Bonus Q&A 16 January 2010 22:55 UTC www.industryweek.com [Source type: FILTERED WITH BAYES]

    ^ It uses a variety of quality tools such as QFD, Taguchi methods, SPC, corrective-action response teams, cause-and-effect analysis, problem-solving methodologies, and fail-safing.
    • Lean manufacturing definition | Lean Manufacturing 16 January 2010 22:55 UTC www.beyondlean.com [Source type: FILTERED WITH BAYES]

    ^ TSSW – Thinking the six sigma way – A mental model for improvement which perceives outcomes through a cause and effect relationship combined with six sigma concepts to solve everyday and business problems.

    .The tools employed at Toyota are often used to expose particular problems that are then dealt with, as each tool's limitations or blindspots are perhaps better understood.^ Our job as a Lean leader is to help expose problems and then make sure people have the skills and the tools to solve these problems.

    .So, for example, Value Stream Mapping focuses upon material and information flow problems (a title built into the Toyota title for this activity) but is not strong on Metrics, Man or Method.^ Value Stream Mapping can be a useful method to better understand our activities, connections and flows.

    ^ This principle is achieved using a process known as Value Stream Mapping which is a method used to understand and record all material and information flow required to bring our product or service to the customer.

    ^ In Lean Manufacturing, waste is identified through a value stream analysis, a process which identifies all activities in the value stream and identifies the specific value they add to the final product.

    .Internally they well know the limits of the tool and understood that it was never intended as the best way to see and analyze every waste or every problem related to quality, downtime, personnel development, cross training related issues, capacity bottlenecks, or anything to do with profits, safety, metrics or morale, etc.^ Specifying tasks to the best way to get the job done in the amount of time available while ensuring the job is done right the first time, every time.
    • Lean Manufacturing Glossary - Michigan Manufacturing Technology Center (MMTC) 16 January 2010 22:55 UTC www.mmtc.org [Source type: FILTERED WITH BAYES]

    ^ Take a group of employees on a waste-walk and focus on what frustrates them, and they’ll see opportunities.

    ^ I am now becoming involved in lean implementation projects -- developing the training, project plans, etc.
    • IndustryWeek - Leadership in Manufacturing: Lean Webcast Bonus Q&A 16 January 2010 22:55 UTC www.industryweek.com [Source type: FILTERED WITH BAYES]

    No one tool can do all of that. .For surfacing these issues other tools are much more widely and effectively used.
  4. Management technique rather than change agents has been a principle in Toyota from the early 1950s when they started emphasizing the development of the production manager's and supervisors' skills set in guiding natural work teams and did not rely upon staff-level change agents to drive improvements.^ I gained much more than expected.
    • Six Sigma Green Belt Certification,Six Sigma Black Belt Certification,Six Sigma Yellow Belt Certification,Six Sigma Certification India 9 October 2009 8:58 UTC www.benchmarksixsigma.com [Source type: FILTERED WITH BAYES]

    ^ Much more than value for money.
    • Six Sigma Green Belt Certification,Six Sigma Black Belt Certification,Six Sigma Yellow Belt Certification,Six Sigma Certification India 9 October 2009 8:58 UTC www.benchmarksixsigma.com [Source type: FILTERED WITH BAYES]

    ^ A manufacturing approach with techniques designed to contribute to the flexibility of a process and thereby reduce the impact of changes in product mix and, to certain extent, volume.
    • Lean Manufacturing Glossary - Michigan Manufacturing Technology Center (MMTC) 16 January 2010 22:55 UTC www.mmtc.org [Source type: FILTERED WITH BAYES]

    .This can manifest itself as a "Push" implementation of Lean rather than "Pull" by the team itself.^ Why is it that companies usually focus only on the Lean tools, rather than on the thinking that is required to correctly deploy the tools?

    ^ The critical step in implementing Lean Manufacturing in our plant was a carefully planned changeover from push scheduling to pull scheduling.

    ^ Teams solving problems and identifying, and eliminating waste tell a leader more about the Lean transformation’s current state than reports.

    .This area of skills development is not that of the change agent specialist, but that of the natural operations work team leader.^ Do our front line leaders have what they need (including good data, skills, tools and our support) to engage their teams in structured problem solving?

    ^ It becomes a valuable mechanism for staying in touch with our managers and team leaders, and keeping in touch with the real operational issues in our business.

    ^ A Lean leader must eliminate the comfort zone, and direct employees to the learning zone, changing the conditions and rules under which they operate.

    .Although less prestigious than the TPS specialists, development of work team supervisors in Toyota is considered an equally, if not more important, topic merely because there are tens of thousands of these individuals.^ These people are tapped to lead individual Six Sigma teams.

    ^ This was accomplished through formation of teams that were trained in work measurement and improvement techniques and expected to develop and continually improve their own work standards and practices.

    ^ JPW: Lean implementation typically requires a lot less capital and hard technology than management was planning to obtain and a lot more hands-on training that management was planning to obtain.
    • IndustryWeek - Leadership in Manufacturing: Lean Webcast Bonus Q&A 16 January 2010 22:55 UTC www.industryweek.com [Source type: FILTERED WITH BAYES]

    .Specifically, it is these manufacturing leaders that are the main focus of training efforts in Toyota since they lead the daily work areas, and they directly and dramatically affect quality, cost, productivity, safety, and morale of the team environment.^ June 2009 - (Free Research) With compliant manufacturing operations, you can deliver quality products to customers consistently and meet good manufacturing practices regulations at the lowest cost possible - all key to leading the competition.
    • Lean Manufacturing Goals - Manufacturing Business Technology Results for Lean Manufacturing Goals 16 January 2010 22:55 UTC researchlibrary.mbtmag.com [Source type: Academic]

    ^ These new kinds of andon boards are very helpful in lean manufacturing as they let you know how well your production is going.

    ^ A visual control device in a production area, typically a lighted overhead display, giving the current status of the production system and alerting team members of emerging problems.
    • Lean manufacturing definition | Lean Manufacturing 16 January 2010 22:55 UTC www.beyondlean.com [Source type: FILTERED WITH BAYES]

    .In many companies implementing Lean the reverse set of priorities is true.^ Norman Bodek, who publishes books on productivity, maintains that many companies have embraced lean, but they "wrestle with a fundamental component of the philosophy: the worker."

    ^ It is found that in general, companies implementing and adhering to lean manufacturing practices significantly boost and increase their manufacturing productivity by as much as 75% to 125%.

    ^ That is why some governments are expected to subsidize training on lean manufacturing and make them free for all companies to learn and implement.

    Emphasis is put on developing the specialist, while the supervisor skill level is expected to somehow develop over time on its own.

Lean services

.Lean, as a concept or brand, has captured the imagination of many in different spheres of activity.^ Using different lean concepts championed by TPS, businesses in need of a little direction should reevaluate their use of kanban, kaizen, and 5S techniques.

^ There are many principles, concepts, tools and techniques that make up an effective Lean Manufacturing system.
  • The Sixth Sigma - Lean Manufacturing Concepts 16 January 2010 22:55 UTC www.sixthsigma.com [Source type: Academic]

Examples of these from many sectors are listed below.
.Lean principles have been successfully applied to call center services to improve live agent call handling.^ There are more and more companies around the world that successfully implement lean manufacturing techniques and principles in their daily operation.

^ Companies that successfully implement lean manufacturing principles .

^ But, applying the principles of lean manufacturing tells us ...

.By combining Agent-assisted Voice solutions and Lean's waste reduction practices, a company reduced handle time, reduced between agent variability, reduced accent barriers, and attained near perfect process adherence.^ Lean production is an attempt to reduce impediments to the smooth flow of production through various techniques, including continuous improvement in productivity and quality ("kaizen"), "just-in-time" (JIT) inventory systems, and training workers to conduct quality control through Quality Circles.

^ In minimizing these wastes, the principles of lean manufacturing employ strategies that focus on improving the production process.

^ Wise companies realize that traditional software development contract practices generate hidden wastes.

[25]
.Lean principles have also found application in software application development and maintenance and other areas of information technology (IT).^ Have you seen applications of lean in software development?
  • IndustryWeek - Leadership in Manufacturing: Lean Webcast Bonus Q&A 16 January 2010 22:55 UTC www.industryweek.com [Source type: FILTERED WITH BAYES]

^ It shows how the "lean principles" of value (as defined by the customer), value stream, flow, pull, and perfection can be applied to all areas of the enterprise.

^ The resulting Lean Programming practices will lead to the highest quality, lowest cost, shortest lead time software development possible.

[26] .More generally, the use of Lean in IT has become known as Lean IT.^ Leaders and managers become more effective by aggressively applying Lean to their job functions.

^ The fear of firings when things become more "efficient," a misplaced notion of waste reduction, hurts lean.

^ This information is generally communicated via color coding and labeling, two useful tools for making anything -- from panelboards to fire extinguishers -- more user-friendly.

.A study conducted on behalf of the Scottish Executive, by Warwick University, in 2005/06 found that Lean methods were applicable to the public sector, but that most results had been achieved using a much more restricted range of techniques than Lean provides.^ I gained much more than expected.
  • Six Sigma Green Belt Certification,Six Sigma Black Belt Certification,Six Sigma Yellow Belt Certification,Six Sigma Certification India 9 October 2009 8:58 UTC www.benchmarksixsigma.com [Source type: FILTERED WITH BAYES]

^ Much more than value for money.
  • Six Sigma Green Belt Certification,Six Sigma Black Belt Certification,Six Sigma Yellow Belt Certification,Six Sigma Certification India 9 October 2009 8:58 UTC www.benchmarksixsigma.com [Source type: FILTERED WITH BAYES]

^ Lean manufacturing techniques flexes this attribute by effectively allowing employees to get used to a system and then do it frequently for more efficiency.

[27]
.The challenge in moving Lean to services is the lack of widely available reference implementations to allow people to see how directly applying lean manufacturing tools and practices can work and the impact it does have.^ LEI runs basic and advanced training in a different region of North America every month on how to implement lean principles in manufacturing, support, logistics, and service processes.
  • Lean Management Accounting Workshop Resolves Conflicts Between Lean Thinking and Traditional Accounting. | Management > Lean Manufacturing from AllBusiness.com 9 October 2009 8:58 UTC www.allbusiness.com [Source type: News]

^ Lean processing, long a staple in manufacturing, provides this opportunity for increasing efficiency within financial services.
  • Lean Production IT Reports, Webcasts and White Papers 12 September 2009 12:10 UTC cramsession.bitpipe.com [Source type: General]

^ If we are correct in our analysis, the potential for dramatically increased rates of hypertension and heart disease exists if lean methods (including outsourcing, longer work hours, understaffing and insecure work) are widely implemented in the labor market.

.This makes it more difficult to build the level of belief seen as necessary for strong implementation.^ Quality Analyst, Accenture This course is not only for the quality department but for all levels of management, it is necessary for every one to understand the concepts to do their respective jobs more efficiently.
  • Six Sigma Green Belt Certification,Six Sigma Black Belt Certification,Six Sigma Yellow Belt Certification,Six Sigma Certification India 9 October 2009 8:58 UTC www.benchmarksixsigma.com [Source type: FILTERED WITH BAYES]

^ As part of the principles of lean manufacturing, customer focus makes sure that customer satisfaction is reached, feedbacks are heard and the necessary changes implemented to satisfy the customer base as a whole .

.However, some research does relate widely recognized examples of success in retail and even airlines to the underlying principles of lean.^ As one of the early and most successful adopters of lean management principals, Wiremold became a popular tour destination for American executives and managers seeking to implement lean principles.
  • Lean Management Accounting Workshop Resolves Conflicts Between Lean Thinking and Traditional Accounting. | Management > Lean Manufacturing from AllBusiness.com 9 October 2009 8:58 UTC www.allbusiness.com [Source type: News]

^ However, the success of lean manufacturing adoption and implementation depends and principally relies on the effective and religious implementation of the simple and easy to do strategic principles.

^ Indeed, some companies and experts on lean manufacturing have realized that their expertise and knowledge about the principles are becoming so in demand.

[15] .Despite this, it remains the case that the direct manufacturing examples of 'techniques' or 'tools' need to be better 'translated' into a service context to support the more prominent approaches of implementation, which has not yet received the level of work or publicity that would give starting points for implementors.^ This course is designed for upper and mid-level production managers who want to learn how to successfully implement Lean Manufacturing concepts in their ...
  • The Sixth Sigma - Lean Manufacturing Concepts 16 January 2010 22:55 UTC www.sixthsigma.com [Source type: Academic]

^ LEI runs basic and advanced training in a different region of North America every month on how to implement lean principles in manufacturing, support, logistics, and service processes.
  • Lean Management Accounting Workshop Resolves Conflicts Between Lean Thinking and Traditional Accounting. | Management > Lean Manufacturing from AllBusiness.com 9 October 2009 8:58 UTC www.allbusiness.com [Source type: News]

^ Lean manufacturing techniques can firm up the company by reducing wastes and making the organization better .

.The upshot of this is that each implementation often 'feels its way' along as must the early industrial engineers of Toyota.^ Study of Toyota Production System from Industrial Engineering Viewpoint , by Shigeo Shingo, Osaka, Japan, Shinsei Printing Co.

^ Toyota Production System, Practical Approach to Production Management , by Yasuhiro Monden, Norcross, Georgia, Industrial Engineering and Management Press.

This places huge importance upon sponsorship to encourage and protect these experimental developments.

Lean Goals

The four goals of Lean manufacturing systems are to:
.
  • Improve quality: In order to stay competitive in today’s marketplace, a company must understand its customers' wants and needs and design processes to meet their expectations and requirements.
  • Eliminate waste: Waste is any activity that consumes time, resources, or space but does not add any value to the product or service.^ This will require a good understanding of waste (and value) from the customer’s perspective and then we will need to be relentlessly pursuing systematic waste elimination on a daily basis.

    ^ Value - The price of the product is solely based on the customer's expectation.

    ^ Any activity that does not add value (that which the customer is not prepared to pay for).
    • Lean Manufacturing Glossary - Michigan Manufacturing Technology Center (MMTC) 16 January 2010 22:55 UTC www.mmtc.org [Source type: FILTERED WITH BAYES]

    .There are seven types of waste:
  1. Overproduction (occurs when production should have stopped)
  2. Waiting (periods of inactivity)
  3. Transport (unnecessary movement of materials)
  4. Extra Processing (rework and reprocessing)
  5. Inventory (excess inventory not directly required for current orders)
  6. Motion (extra steps taken by employees due to inefficient layout)
  7. Defects (do not conform to specifications or expectations)
  • Reduce time: Reducing the time it takes to finish an activity from start to finish is one of the most effective ways to eliminate waste and lower costs.
  • Reduce total costs: To minimize cost, a company must produce only to customer demand.^ The task of taking a specific product from raw materials to a finished product in the hands of the customer.
    • Lean Manufacturing Glossary - Michigan Manufacturing Technology Center (MMTC) 16 January 2010 22:55 UTC www.mmtc.org [Source type: FILTERED WITH BAYES]

    ^ Transportation - Unnecessary transportation of products or materials from one location to another .

    ^ Its is usually expressed as specifications, requirements or expectations.

    Overproduction increases a company’s inventory costs due to storage needs.

Steps to achieve lean systems

The following steps should be implemented in order to create the ideal lean manufacturing system: [2]:
  1. Design a simple manufacturing system
  2. Recognize that there is always room for improvement
  3. Continuously improve the lean manufacturing system design

Design a simple manufacturing system

.A fundamental principle of lean manufacturing is demand-based flow manufacturing.^ There are more and more companies around the world that successfully implement lean manufacturing techniques and principles in their daily operation.

^ In minimizing these wastes, the principles of lean manufacturing employ strategies that focus on improving the production process.

^ From analyzing the business process to reviewing the most efficient points, as one of the principles of lean manufacturing, this changes how the business is handled from the very foundations.

.In this type of production setting, inventory is only pulled through each production center when it is needed to meet a customer’s order.^ A situation in which products proceed, one complete product at a time, through various operations in design, order taking, and production, without interruptions, backflows, or scrap.
  • Lean manufacturing definition | Lean Manufacturing 16 January 2010 22:55 UTC www.beyondlean.com [Source type: FILTERED WITH BAYES]

^ The length of time from the start of production and assembly operations for a particular (finished) product to the completion of all manufacturing, assembly, and testing for that product or specific customer order.
  • Lean manufacturing definition | Lean Manufacturing 16 January 2010 22:55 UTC www.beyondlean.com [Source type: FILTERED WITH BAYES]

^ In many "pull" systems, a customer order/shipment date triggers final assembly, which in turn forces replenishment of component WIP inventory at upstream stages of production.
  • Lean manufacturing definition | Lean Manufacturing 16 January 2010 22:55 UTC www.beyondlean.com [Source type: FILTERED WITH BAYES]

The benefits of this goal include: [3]:
  • decreased cycle time
  • less inventory
  • increased productivity
  • increased capital equipment utilization

There is always room for improvement

.The core of lean is founded on the concept of continuous product and process improvement and the elimination of non-value added activities.^ Analyzing the value stream to identify value added and non-value added activities.
  • Lean Manufacturing Glossary - Michigan Manufacturing Technology Center (MMTC) 16 January 2010 22:55 UTC www.mmtc.org [Source type: FILTERED WITH BAYES]

^ He emphasized a culture of continuous improvement of both processes and products.

^ This course is designed for upper and mid-level production managers who want to learn how to successfully implement Lean Manufacturing concepts in their ...
  • The Sixth Sigma - Lean Manufacturing Concepts 16 January 2010 22:55 UTC www.sixthsigma.com [Source type: Academic]

“The .Value adding activities are simply only those things the customer is willing to pay for, everything else is waste, and should be eliminated, simplified, reduced, or integrated”(Rizzardo, 2003).^ This is what the customers is willing to pay for.

^ Lean IT: The Time for Transformation is Now sponsored by CA ANALYST REPORT - Many institutions are investigating opportunities to create more value for customers by eliminating or reducing non-value-adding activities.
  • Lean Production IT Reports, Webcasts and White Papers 12 September 2009 12:10 UTC cramsession.bitpipe.com [Source type: General]

^ Value-added should be calculated by subtracting cost of purchased materials and services from value of shipments.
  • Lean manufacturing definition | Lean Manufacturing 16 January 2010 22:55 UTC www.beyondlean.com [Source type: FILTERED WITH BAYES]

.Improving the flow of material through new ideal system layouts at the customer's required rate would reduce waste in material movement and inventory.^ Lean production is an attempt to reduce impediments to the smooth flow of production through various techniques, including continuous improvement in productivity and quality ("kaizen"), "just-in-time" (JIT) inventory systems, and training workers to conduct quality control through Quality Circles.

^ This will require a good understanding of waste (and value) from the customer’s perspective and then we will need to be relentlessly pursuing systematic waste elimination on a daily basis.

^ New technologies had to be developed to further enhance these communication tools and reduce more waste.

[4]

Continuously improve

A continuous improvement mindset is essential to reach a company's goals. .The term "continuous improvement" means incremental improvement of products, processes, or services over time, with the goal of reducing waste to improve workplace functionality, customer service, or product performance (Suzaki, 1987).^ He emphasized a culture of continuous improvement of both processes and products.

^ In minimizing these wastes, the principles of lean manufacturing employ strategies that focus on improving the production process.

^ He taught the Japanese managers how to empower production workers to investigate problems and systematically improve processes.

Stephen Shortell (Professor of Health Services Management and Organisational Behaviour – Berkeley University, California) states:-
“For improvement to flourish it must be carefully cultivated in a rich soil bed (a receptive organisation), given constant attention (sustained leadership), assured the right amounts of light (training and support) and water (measurement and data) and protected from damaging."

Measure

A set of performance metrics which is considered to fit well in a Lean environment is overall equipment effectiveness, or OEE.

See also

Closely related methodologies

Predictive validation techniques

Terminology

Related engineering disciplines

Areas of implementation outside production

Other

References

  1. ^ a b Womack, James P.; Daniel T. Jones, and Daniel Roos (1990). The Machine That Changed the World.  
  2. ^ Holweg, Matthias (2007). "The genealogy of lean production". Journal of Operations Management 25 (2): 420–437.  
  3. ^ Bailey, David. "Automotive News calls Toyota world No 1 car maker". Reuters.com. Reuters. http://www.reuters.com/article/businessNews/idUSN2424076820080124. Retrieved 19 April 2008.  
  4. ^ Krafcik, John F. (1988). "Triumph of the lean production system". Sloan Management Review 30 (1): 41–52.  
  5. ^ Holweg, Matthias (2007). "The genealogy of lean production". Journal of Operations Management 25 (2): 420–437.  
  6. ^ Ohno, Taiichi (1988). Toyota Production System. Productivity Press. p. 8. ISBN 0-915299-14-3.  
  7. ^ Taichi Ohno (1988), p 4
  8. ^ Taichi Ohno (1988), p 6
  9. ^ "Problems continue at Heathrow's Terminal 5", New York Times, March 31, 2008 article[1]
  10. ^ Andrew Dillon, translator, 1987. The Sayings of Shigeo Shingo: Key Strategies for Plant Improvement).
  11. ^ (Charles Buxton Going, preface to Arnold and Faurote, Ford Methods and the Ford Shops (1915))
  12. ^ Ford, Henry; with Crowther, Samuel (1922), My Life and Work, Garden City, New York, USA: Garden City Publishing Company, Inc, http://www.gutenberg.net/etext/7213   Various republications, including ISBN 9781406500189. Original is public domain in U.S.
  13. ^ Bennett, Harry; with Marcus, Paul (1951), We Never Called Him Henry, New York: Fawcett Publications, LCCN 51-036122  
  14. ^ Womack, James P.; Daniel T. Jones (2003). Lean Thinking. Free Press.  
  15. ^ a b Ruffa, Stephen A. (2008). Going Lean: How the Best Companies Apply Lean Manufacturing Principles to Shatter Uncertainty, Drive Innovation, and Maximize Profits. AMACOM. ISBN 0-8144-1057-X. http://books.google.com/books?id=_Q7OGDd61hkC.  
  16. ^ Hounshell, David A. (1984), From the American system to mass production, 1800-1932: The development of manufacturing technology in the United States, Baltimore, Maryland, USA: Johns Hopkins University Press, LCCN 83-016269, ISBN 978-0-8018-2975-8  . pp 248 ff.
  17. ^ Toyota Production System, Taichi Ohno, Productivity Press, 1988,, p. 58
  18. ^ Womack, James P.; Daniel T. Jones (2003). Lean Thinking. Free Press. p. 352.  
  19. ^ Bicheno, John; Matthias Holweg (2009). The Lean Toolbox. PICSIE Books. ISBN 978-0954124458.  
  20. ^ Toyota Vision and Philosophy
  21. ^ Pat Lancaster of Lean Thinking's Lanchester Technologies reference implementation
  22. ^ Maskell & Baggaley (December 19, 2003). "Practical Lean Accounting". Productivity Press, New York, NY.  
  23. ^ The Gold Mine, F & M Ballé, The Lean Enterprise Institute, 2005, p196
  24. ^ Michael Ballé & Freddy Ballé (2009) The Lean Manager, Lean Enterprise Institute
  25. ^ Adsit, Dennis. "Cutting Edge Methods Target Real Call Center Waste". isixsigma.com. http://www.isixsigma.com/library/content/c070611a.asp. Retrieved 19 April 2008.  
  26. ^ Hanna, Julia. “Bringing ‘Lean’ Principles to Service Industries”. HBS Working Knowledge. October 22, 2007. (Summary article based on published research of Professor David Upton of Harvard Business School and doctoral student Bradley Staats: Staats, Bradley R., and David M. Upton. “Lean Principles, Learning, and Software Production: Evidence from Indian Software Services.”. Harvard Business School Working Paper. No. 08-001. July 2007. (Revised July 2008, March 2009.)
  27. ^ Radnor, Dr Zoe; Paul Walley, Andrew Stephens, Giovanni Bucci. "Evaluation Of The Lean Approach To Business Management And Its Use In The Public Sector". scotland.gov.uk. http://www.scotland.gov.uk/Publications/2006/06/13162106/0. Retrieved 19 April 2008.  
  • MacInnes, Richard L. (2002) The Lean Enterprise Memory Jogger
  • Page, Julian (2003) Implementing Lean Manufacturing Techniques

External links


Citable sentences

Up to date as of December 19, 2010

Here are sentences from other pages on Lean manufacturing, which are similar to those in the above article.








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