Lean Manufacturing

Eliminating waste and maximizing value through continuous improvement.

The 8 Wastes

Learn to identify and eliminate:

Defects: Rework, scrap, corrections
Overproduction: Making more than needed
Waiting: Idle time, delays
Non-Utilized Talent: Not using employee skills
Transportation: Unnecessary movement of materials
Inventory: Excess stock, WIP
Motion: Unnecessary human movement
Extra Processing: More work than required

5S Workplace Organization

1. Sort (Seiri):

Remove unnecessary items
Red tag items for removal
Keep only what's needed
Clear workspace clutter

2. Set in Order (Seiton):

A place for everything
Shadow boards for tools
Label all locations
Visual controls
Easy access to frequently used items

3. Shine (Seiso):

Clean work areas daily
Inspect while cleaning
Maintain equipment
Identify problems early

4. Standardize (Seiketsu):

Create standards
Document best practices
Visual management
Sustain improvements

5. Sustain (Shitsuke):

Make it a habit
Regular audits
Continuous improvement
Recognize excellence

Value Stream Mapping

Understanding process flow:

Identify all process steps
Map material and information flow
Calculate value-added time
Identify waste
Create future state map
Implement improvements

Standard Work

Best way to do a job:

Documented procedures
Takt time-based
Work sequence
Standard WIP levels
Reviewed and updated regularly
Basis for improvement

Visual Management

Making problems visible:

Andon lights (red/yellow/green)
Production boards
Quality metrics displays
Safety scoreboards
Schedule boards
Standard work charts

Kaizen Events

Focused improvement projects:

Typically 3-5 days
Cross-functional team
Specific problem or area
Rapid implementation
Document results
Sustain improvements

Kaizen event phases:

Plan and prepare
Current state analysis
Generate ideas
Implement solutions
Standardize
Follow up

Continuous Flow

Eliminating batching:

One-piece flow where possible
Reduce batch sizes
Balance workstations
Eliminate bottlenecks
Quick changeovers

Pull Systems

Kanban replenishment:

Produce based on demand
Visual signals (cards, bins)
Replenish only what's consumed
Reduce inventory
Prevent overproduction

TPM (Total Productive Maintenance)

Equipment reliability:

Autonomous maintenance (operators)
Scheduled maintenance
Preventive maintenance
Predictive maintenance
OEE tracking (Overall Equipment Effectiveness)

Problem Solving

A3 Thinking:

Define the problem
Current situation analysis
Goal/target condition
Root cause analysis (5 Whys)
Countermeasures
Implementation plan
Follow-up

Employee Involvement

Everyone can contribute:

Suggestion program
Kaizen teams
Problem-solving training
Recognition and rewards
Empowerment to stop line

Metrics and KPIs

Measuring improvement:

On-time delivery %
First pass yield
Cycle time reduction
Inventory turns
Lead time reduction
Space utilization
Cost per unit
Safety metrics

Getting Started

How to participate:

Attend lean training
Join improvement teams
Submit improvement ideas
Practice 5S daily
Ask "Why?" when you see waste
Challenge the status quo

Lean Manufacturing Principles