Lean

Lean or Lean Thinking is a systematic method for waste minimization within a manufacturing system without sacrificing productivity. Lean also takes into account waste created through overburden and waste created through unevenness in workloads. Lean methodologies are derived from the Toyota Production System (TPS).

History

The concept of Lean was first introduced by Toyota in the 1930s. The principles of Lean were developed as a response to the challenges of post-war Japanese manufacturing. The term "Lean" was coined by John Krafcik in his 1988 article, "Triumph of the Lean Production System."

Principles

Lean is based on five principles:

1. Identify Value: This involves understanding what the customer values in the product or service.
2. Map the Value Stream: This involves identifying all the steps in the process and eliminating those that do not add value.
3. Create Flow: This involves ensuring that the product or service flows smoothly through the process without delays or bottlenecks.
4. Establish Pull: This involves producing only what the customer needs when they need it.
5. Pursue Perfection: This involves continuously improving the process to eliminate waste and increase value.

Lean Tools

There are several tools used in Lean methodologies, including:

1. Kanban: A visual system for managing work as it moves through a process.
2. 5S: A system for organizing spaces so work can be performed efficiently, effectively, and safely.
3. Kaizen: A strategy where all employees work together proactively to achieve regular, incremental improvements in the manufacturing process.
4. Poka-yoke: A mechanism that helps an equipment operator avoid mistakes.

Benefits

Lean methodologies can lead to significant benefits, including reduced waste, improved efficiency, increased productivity, and improved customer satisfaction.

Criticisms

Despite its benefits, Lean has been criticized for its potential to over-emphasize efficiency at the expense of other important business considerations, such as employee satisfaction and environmental sustainability.

See Also

• Six Sigma
• Total Quality Management
• Just In Time Production