What Does it Mean to Be Lean? 

A systematic approach to identifying and eliminating waste (non-value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection. 

KAIZEN

 Where’s the Waste? 

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Overproduction

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Waiting

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Transportation

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Process Itself

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Excessive Inventory

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Motion

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Making Defective Product

Lean Factory Building Blocks

 

Standardized Work 

Operations safely carried out with all task organized in the best known sequence and by using the most effective combination of resources 

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People

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Materials

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Methods

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Machines

 

Workplace Organization

5 “S’s”

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Sort
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Keep only what is needed in your area

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Stabilize
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A place for everything and everything in its place

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Shine
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Clean up the workplace

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Standardize
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Develop system (rules) to maintain what has been done

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Sustain
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Self discipline to maintain established procedures

 

Visual Systems

Visual Controls are simple signals that provide an immediate understanding of a situation or condition.  They are efficient, self regulating, and worker managed.  Examples include: 

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Pictures, diagrams        

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Color coded dies, tools, pallets

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Lines on the floor to delineate storage areas, walk ways, work areas, etc.

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Improved lighting

 

Quality at the Source

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Source Inspection: Operators must be certain that the product they are passing to the next workstation is of acceptable quality.  

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Operators must be given the means to perform inspection at the source, before they pass it along.

 

Quality at the Source

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Samples or established standards are visible tools that can be used in the cell for such purposes

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Process Documentation defining quality inspection requirements for each work station may need to be developed

Push vs. Pull Systems

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Push System

- Resources are provided to the consumer based on forecasts or schedules.

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Pull System

– A method of controlling the flow of resources by replacing only what has been consumed.

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