5 Methods for a Lean Manufacturing Process
Lean is the way of the future. Get on top of your production waste by trying out one or more of these lean manufacturing methods.
Manufacturing continues to change with technology and new ideas, and so manufacturers need to stay abreast of these innovations to remain competitive in their industry.
Lean manufacturing is one of the most important developments in manufacturing history, and it continues to inspire big-name manufacturers like Toyota today.
To start going lean and improve your production processes, learn more about the history of lean and popular methods below.
Using lean manufacturing methods
What is lean manufacturing?
Lean manufacturing is a methodology that applies practices and principles to reduce waste, minimize downtime, increase cost savings, and produce sustainably.
Although there is evidence of lean manufacturing methods back in the 15th century, the first real application of lean was in Henry Ford’s production line in 1913. In the 1930s and after World War II, Toyota led the world in lean manufacturing, providing monumental lean philosophies such as 5S.
Since then, lean manufacturing has developed into innovative philosophies that have changed how we manufacture today.
Benefits of going lean
The reason why manufacturing companies continue to use lean methodology is because of the numerous benefits it provides. Some of these benefits include:
Reduced lead time: Efficient manufacturing reduces lead time, shipping your product out faster for higher customer satisfaction.
Improved product quality: Product quality is improved when wasted motions and materials are removed. Like Antoine de Saint-Exupery said, “Perfection is achieved, not when there is nothing more to add, but when there is nothing left to take away.”
Less product waste: As mentioned, lean manufacturing reduces product waste by removing unnecessary materials during the manufacturing process.
Minimal downtime: Less time is wasted during lean manufacturing since processes are more efficient.
Increased cost savings: Because product quality is improved, downtime is minimized, and fewer materials are wasted, manufacturers see an increase in cost savings when they go lean.
Sustainability: Lean manufacturing is far more sustainable than traditional manufacturing, which is a necessity for consumers who demand better from companies.
To reap the benefits of lean thinking, learn five different methods of lean manufacturing below.
5 methods for a lean manufacturing process
1. KANBAN
The purpose of Kanban is to manage workflow processes in a visual manner. Kanban is Japanese for “sign,” and it was developed by Toyota in the 1940s.
In order to add Kanban thinking to your production line, start implementing visual cues of the progress of your products on the warehouse floor. This could be a digital board or a physical board that includes categories such as “Ready to Start,” “Working,” “Waiting,” “Review,” and “Done.”
2. KAIZEN
Kaizen is a form of Japanese business philosophy meaning “continuous improvement” or “change for the better." This lean method focuses on holistically improving product quality, company culture, and production efficiency.
It is a cycle of progression that constantly analyses production inefficiencies to improve manufacturing. By tracking and measuring progress, manufacturers can create leaner production lines.
3. CELLULAR MANUFACTURING
Cellular manufacturing is applied to the layout of the manufacturing floor. It is the strategic arrangement of equipment and processes to reduce waste.
Before cellular manufacturing, the flow of production was jumbled up, jumping around from one place to another throughout the plant. Now, manufacturers use cellular manufacturing to provide a seamless workflow through layouts such as the U-shape, straight line, or inverted U-shape.
4. 3P
The Ps of 3P stand for Production Preparation Process. By eliminating waste through prototyping, manufacturers can improve product quality and minimize downtime on the production floor.
NRTC Automation provides prototyping services to help you create a leaner company. Reach out to us here to learn more about what we can do for you.
5. 5S
Last but not least, 5S is another popular method of lean. It stands for Sort, Set in Order, Shine, Standardize, and Sustain. This method of lean manufacturing also originated in Japan and centers efficiency around necessary versus unnecessary processes.
It’s similar to adding key hooks near your front door so you don’t lose your car keys. By putting everything in its place, manufacturers can reduce downtime and improve productivity.
Stay competitive in 2021 by getting leaner
To stay competitive in your industry, start implementing more lean methodology into your manufacturing processes. Not only will you see an increase in cost savings and productivity, but you’ll have happier customers and greater demand for your product.
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Schedule a free consultation with NRTC to learn how we can free up time and resources on your production floor.
