Table of contents
LEAN Manufacturing Practices – What Are They?
Lean manufacturingLean manufacturing (also known as lean production, just-i... Learn More... practices are a method that minimizes wasteMuda (無駄, on'yomi reading) is a ... Learn More... in manufacturing processes while increasing productivity. Anything that customers don’t believe adds value or is not worth paying for is considered waste. Lean manufacturingLEAN Definition LEAN is a production method aimed primarily ... Learn More... concepts and principles have many benefits, including reduced lead times and lower operating costs as well as improved product quality which is why companies that use leanLEAN Definition LEAN is a production method aimed primarily ... Learn More... manufacturing see great benefits.
More than ever, speed to market, operational efficiency, and flexibility are key factors in manufacturing’s volatile, fast-paced environment. Lean manufacturing is being adopted by companies to gain a competitive edge.
Lean manufacturing, also known as lean production or lean, can be enabled by organizations in many fields. Toyota, Intel, and John Deere are just a few of the well-known companies that use lean manufacturing. This approach was developed from the Toyota Production SystemTPS – The Toyota Production System The Toyota Production ... Learn More.... It is still being used by many other companies, including Nike and John Deere. Enterprise resource planning ( ERP), can also benefit by using a lean production method.
Lean manufacturing is founded on several principles such as Kaizen or continuous improvementContinuous improvement (or Kaizen) is a way to identify oppo... Learn More....
Lean manufacturing was first introduced to the West by the 1990 publication The Machine that Changed the World. This was based upon an MIT study on the future of the automobile, and detailed Toyota’s lean production processThere are many ways to organize your lean six sigma processe.... Lean principles have influenced many industries, not only manufacturing but also software development and healthcare.
Five principles of lean manufacturing

Lean Thinking: Banish Waste and Create Wealth for Your Corporation is a widely-referenced book that laid out five principles to lean. It was published in 1996. Many in the field refer to it as the core principles. They are the value stream (value stream), flow (pull), and perfection. These are used now as the foundation for lean implementation.
1. Value is best understood from the perspective of the customer. The producer creates value, but the customer defines it. Understanding the customer’s value can help companies determine the amount of money they are willing to spend on their products or services.
To achieve the best price for the customer, the company must eliminate all waste and costs from its business processes. This will allow the company to make the most of its profits.
2. The value stream can be mapped. This principle involves recording and analyzing the flow of information and materials necessary to create a product or service. The goal is to identify waste and improve the process. Value stream mappingWhat is a Value Stream Map? Six Sigma's Value Stream Map is ... Learn More... covers the entire product’s lifecycle, including raw materials and disposal.
Each stage must be inspected by companies to identify waste. Any waste that doesn’t add value should be eliminated. Lean thinking suggests that supply chain alignment is part of this effort.
3. Facilitate flow. Reduce functional barriers and find ways to increase lead time. This helps to ensure smooth processes from order receipt through delivery. The elimination of waste is dependent on flow. Lean manufacturing is about avoiding interruptions in production and creating a unified and integrated set that allows activities to move in a continuous stream.
4. Set up a pull system. This allows you to only take on new work when it is needed. Lean manufacturing employs a pull system rather than a push system.
In manufacturing resource planning (MRP), push systems are used. A push system allows for inventoryMuda (無駄, on'yomi reading) is a ... Learn More... to be planned in advance and product manufacturing can take place according to that forecast. Forecasts can be inaccurate and lead to swings in inventory levels, disrupted schedules, and poor customer service.
Lean manufacturing, which is different from MRP, is based on a pull system. This means that nothing is bought or manufactured until there is demand. The pull is based on flexibility and communication.
5. Kaizen is a way to strive for perfection through continuous process improvement. Lean manufacturing is based on the idea of continuously striving to achieve perfection. This involves identifying the root causes and eliminating waste from the value stream.
The eight wastes in lean production
The Toyota Production SystemTPS – The Toyota Production System The Toyota Production ... Learn More... identified seven “wastes” (processes and resources that aren’t adding value to the customer) These seven wastesMuda (無駄, on'yomi reading) is a ... Learn More... include:
- Unnecessary transportation
- Stock surplus
- The unnecessary motionMuda (無駄, on'yomi reading) is a ... Learn More... of equipment, people, or machinery
- WaitingMuda (無駄, on'yomi reading) is a ... Learn More..., whether it’s people or equipment that is idle;
- Over-production of a product
- Over-processingMuda (無駄, on'yomi reading) is a ... Learn More... is putting more effort into a product than the customer requires. This includes designs that are too complex or require expensive machinery to add unnecessary features.
- These defectsMuda (無駄, on'yomi reading) is a ... Learn More... can be costly and time-consuming to correct.
Many lean practitioners, even though it was not included in the original Toyota Production System, point out an eighth waste: the waste of talent and ingenuity.
7 lean manufacturing concepts and tools
Lean manufacturing demands that you constantly seek to reduce any product that doesn’t add value, which is waste. Continuous improvement is the core of lean manufacturing.
Lean also relies upon the following concepts and processes:
- Heijunka is a production leveling or smoothing process that aims to create a continuous flowDelivering the right value to your customers at the right mo... Learn More... in production, releasing work to plants at the appropriate rate and avoiding interruptions.
- 5SLean 5S Visual Management Training The Lean 5S training tool... Learn More...: A collection of methods for organizing workspaces to make them more efficient, productive, and safer for employees. Organization and cleanliness are the keys to 5S.
- Kanban is a signal that streamlines processes and creates just-in-time delivery. A signal can be either physical (e.g., a tag, empty bin) or electronic (e.g., sent through a computer system).
- JidokaBy its definition, Jidoka is a widely adopted Lean method ut... Learn More... is a method for identifying abnormalities, stopping work until they can be corrected, and then solving the problem.
- AndonAndon Board Andon board is a system that informs employees ... Learn More...: A visual aid such as a flashing lamp that alerts workers when there is a problem.
- Poka-yoke: A mechanism to protect against human errorStatistics error The dual dimension of error statistics is p... Learn More.... It may include an indicator light that lights up if you miss a step, a sign that indicates that a bolt has been tightened correctly, or a system that blocks your next step until you have completed all previous steps.
- The time it takes to make a part or complete an operation.

Six Sigma vs. Lean
Six SigmaSix Sigma Definition: Six Sigma is a set of techniques and t... Learn More... is a method of data-driven management similar to lean. It aims to improve quality by identifying the defects in a process and eliminating them until they are eliminated.
Both Six Sigma and Lean are aimed at eliminating waste. Both Six Sigma and Lean have different methods because they deal with the root causes of waste differently.
Six Sigma focuses on process variation. Lean states that waste is created by extra steps and processes that customers don’t value. Six Sigma, however, says that it’s caused by customer-specific features. Both approaches can be combined to create a data-driven approach called Six Sigma.
Lean Manufacturing: A Practice
Operational efficiency is key in the manufacturing industry. Lean manufacturing offers a method to minimize waste in manufacturing systems, which allows companies to achieve the operational efficiency that they need to stay ahead of their competition.
What practices do you use for your projects?
Let us know in the comments below.