Lean Manufacturing is a methodology and management strategy in production practices that focuses on the use and empowerment of resources to create value for customers by reducing waste by using manufacturing systems.
Lean is adopted from the Toyota Production System (TPS), through the foundation of the basic principles of Lean Manufacturing System is expected to be implemented before practicing lean manufacturing in the company so that lean production practices can increase the productivity of the company.
Lean principles are derived from the Japanese manufacturing industry. The term was first coined by John Krafcik in his 1988 article, “Triumph of the Lean Production System”, based on his master’s thesis at the MIT Sloan School of Management. Krafcik had been a quality engineer in the Toyota-GM NUMMI joint venture in California before joining MIT for MBA studies. Krafcik’s research was continued by the International Motor Vehicle Program (IMVP) at MIT, which produced the international best-selling book co-authored by James P. Womack, Daniel Jones, and Daniel Roos called The Machine That Changed the World. A complete historical account of the IMVP and how the term “lean” was coined is given by Holweg (2007).
The implementation of Lean Manufacturing (its methods and tools) is done continuously to create improvements to the process and innovation in the company, so that the company does what is called continuous improvement (CI) to achieve operational excellence and customer intimacy.
8 Waste in Lean Manufacturing
Waste Transport – consists of unnecessary displacements or transportation such as temporary placement, reassembling, moving goods
Waste Excess Inventory – excess inventory, stock or inventory
Waste Movement – time used to search, then inefficient and not ergonomic movements
Waste Waiting – This waste includes activities such as auto attendance, waiting for goods to come and so on
Waste Excess Production – produces a product that exceeds demand, or earlier than schedule
Waste Over process – adding process that is not required for product goods will only increase production costs
Waste Defect – rework no value added (customer does not pay)
Waste skill – management does not utilize the skills and skills of staff properly even not involving them in improvement projects in the organization
Lean Basic Principles
Like any other methodology in the world, Lean has basic concepts or principles. This principle is evolving into all the roadmaps and tools that we now know. Here are the basic principles of Lean:
Please provide VALUE according to customer needs and requests.
Identify VALUE STREAM for each product / service.
Create a process flow into a routine and continuous stage (continuous FLOW).
Apply pull system (PULL system) in process.
Do it consistently until the perfect process (ZERO-WASTE) is achieved.