Introduction to Lean manufacturing

An approach to manufacturing aiming at eliminating or reducing activities which do not add value from the customer’s point of view.

Benefits of Lean manufacturing

The benefits of Lean manufacturing for the company are:

• Increase in customer satisfaction because of reduced lead time.
• Increase in stock turns because of reduced WIP.
• Increase in quality because of "right first time" policy.
• Increase in flexibility because of well trained and motivated workforce.

The benefits of Lean manufacturing for the workforce are:

• Improved working conditions.
• Improved work satisfaction through involvement.
• Improved job security because of better competitiveness.

Background to Lean manufacturing

Some of the ideas of Lean manufacturing go back a long time. For instance, when Henry Ford started to build his famous Ford Model T at the beginning of the 20th century, he incorporated the ideas of standardised parts and assembly lines in his production system, principles which can still be found in Lean manufacturing. Another influential figure in the development of Lean manufacturing was Dr Deming, an American professor and consultant. He taught Japanese top management how to improve design, product quality, testing and sales. Taiichi Ohno at Toyota is widely credited with building on these and similar principles to develop the Toyota Production System which is better known today as Lean production.

Although Lean manufacturing uses some aspects of mass production it rejects others. Both mass production and Lean manufacturing break down the manufacturing process into individual tasks. In mass production they can be very small and prescribed by someone who is not working on the job. Lean manufacturing acknowledges the experience of the operator who is actually doing the task by asking him to document the best way of performing his task in a standard operation. He is also trained in the tasks coming immediately before and after his so that he is flexible enough to be able to move to where the need is greater.

With the help of operators the whole production is streamlined to achieve minimum WIP, minimum lead time as well as maximum quality and flexibility. The supervisor becomes the team leader, i.e. going from telling the operators what to do, to asking them how he can support them. This means that the operators have to be properly trained and given plenty of information in order to make the right decisions.

Core themes of Lean manufacturing

The top priority of Lean manufacturing is the elimination of waste. Well-motivated teams and good communication support this aim. These pillars are based on the five principles of Lean manufacturing:

Some Lean manufacturing tools

Why employ a consultant?

This is a fair question. Frequently consultants are employed because they:

• Provide theoretical knowledge
• Have practical experience

However, in Lean they have an additional function. They are facilitators, i.e.:

• They keep your eye on the next mile stone; and
• Ensure that you take the necessary steps to reach it.
• Our aim is it to help our clients to learn how to learn so that they become independent.

Next Lean manufacturing workshop

• Date: See list below (registration closes 3 days before date of workshop)
• Time: 8:45 for 9:15 - 15:30
• Venue: Airedale House, Clayton Wood Rise, West Park, Leeds, LS16 6RF (subject to revision)
• Fee: £350 per person (-20% for the first five to register for each workshop) including:
  • Refreshments and buffet lunch and
  • Optional half day on site follow-up visit

Courses

Here is a list of in-house courses that can be delivered individually or in any combination (with or without implementation support):

Notes: Fees may change without prior notice. Implementation support only included where indicated, otherwise additional fees are required.

Register/information request for courses

Please contact us for more information.