Manufacturing is one of the most important processes that are directly or indirectly associated with all the developments we are making every day. In simple terms, it is the collection of different processes aimed at the conversion of raw materials into finished products. Manufacturing is a long process comprising of several complex processes, each of which requires absolute perfection.
What is Lean Manufacturing?
The word lean signifies a small amount. The whole principle of lean manufacturing is an efficient use of both money and time. Lean manufacturing encouraged investing a small amount of money in purchasing the right amount of raw materials for production. The production is generally a smooth and continuous one.
What are the prime objectives of Lean Manufacturing?
The objectives of lean manufacturing are:
Efficient use of raw materials
Improve build quality
Improve Delivery Time
Efficient waste management
Now, how to achieve these objectives?
Well, it can be done by implementing the following methods
Kaizen Rapid Improvement Process
The foundation factor of Lean manufacturing is the Kaizen process. Kaizen process encourages the implementation of small changes regularly and sustained over a long period of time to attain improvements significantly. Kaizen process encourages workers from all levels to work in union and use various analytical methods to solve any problem.
The 5S process encourages the minimal generation of waste to boost up productivity by maintaining proper order in the workplace and also uses visual cues for improving the consistency of the results achieved. The five components of the 5S system include
Total Productive Maintainance(TPM)
TPM encourages the maximization of the overall effectiveness and precision of the different types of equipment across all levels by tuning up the existing processes and by reducing the chances of any potential error.
Cellular Manufacturing (also known as One-Piece Flow System) encourages the arrangement of all work stations and equipment in a product-aligned sequence which facilitates the smooth flow of raw materials and components to prevent any delay in the production process.
Kanban (also known as Just-in-time production) encourages the production of products only when the customer demands. This helps in reducing the amount of waste generated.
Developed by Motorola, Six-Sigma comprises of a set of structured, data-driven methods to analyze different processes systematically aimed at reducing the frequency of product variation.
Few other methods for achieving the objectives of lean manufacturing are:
Lean Enterprise Supplier Network