Lean Manufacturing and Lean Services 

Lean Manufacturing and Lean Services is a process philosophy that guides a practical approach to continuous performance improvement.

Historically, firms have been organised in functional silos with poorly defined processes. Successes at at world class organisations have defined new models of performance and operational efficiency. One solution has been the development of Lean, which is intolerant of waste.

Those early adoption companies have evolved a new methodology which sees Lean embedded in the Six Sigma initiative.

What is Lean Manufacturing and Lean Services?

Lean manufacturing and Lean services is based on the notion that wherever work is done, whether operational or transactional in nature, waste is being generated. By applying Lean tools and techniques, an organisation begins to manage its processes to an optimal level. By focusing on the identification and elimination of waste, processes flow continuously.

Lean manufacturing and Lean services encompass less analysis such as Six Sigma DMAIC or DFSS, and relies greatly on a team based approach. This facilitates a quick understanding of the process, identification and elimination of waste. The outcome is an effective and efficiently running process and ultimately a more profitable business.

Lean is a flexible methodology that can be used at all level within and around an organisation. It is not a long, complicated methodology based on statistical analysis.

Lean Manufacturing and Lean Services Principles

Five principles for Lean are:

  1. Specify value by product or service from a business perspective. 
  2. Identify the value stream for each product and service.
  3. Make value flow without interruption.
  4. Let the customer pull value from the supplier. 
  5. Strive for perfection. 

Lean Manufacturing and Lean Services Excellence objectives are set top down:

  1. Deliver services that customers ask for, when and where they need them.
  2. Manage the life-cycle costs of products and services.
  3. Deviler best possible appropriate quality through innovation.

Lean Manufacturing and Lean Services Excellence is delivered bottom-up

  1. nnecessary effort does not add value to customers.
  2. Unleveled or unevenness is waste resulting from time, quality, and demand Variation.
  3. Overburdened resources (e.g. employees, equipment etc.)  results from inadequate planning. and create inefficiency.

Lean Manufacturing and Lean Services Excellence is sustained when everyone's efforts are synchroniced

  1. The bottom-up perspective employes tools and techniques to optimize processes.
  2. The top-down perspective aligns process optimizations effort to overall business performance objectives.

Lean Manufacturing and Lean Services Tools & Techniques

Some of the typical Lean Manufacturing and Lean Services tools and techniques employed include:

  • Five S 
  • Theory of Constraints 
  • Continuous Flow  
  •  Job / Load Leveling
  • Takt time 
  •  Value Stream Mapping - current state Process mapping. 
  • Analysis Value Stream Mapping - Future state Continuous Improvement Implement
  • Baseline data  
  • Spaghetti Charting 
  •  Time Study Analysis  
  • Production Capacity 
  • validate and standardize 
  •  Visual Workplace 
  •  SMED 
  •  Kaizen 
  •  and more

click here to view the Lean glossary page