What is Lean Manufacturing?

Table of Contents

• What is Lean Manufacturing.

• Where it Comes From
• Who Invented It
• Purpose of Lean
• How Lean Manufacturing Works
• 5 Principles of Lean Manufacturing
• Lean Tools and Concepts
• How Can it Be Implemented
• Challenges and Solutions in Lean Implementation
• Future of Lean Manufacturing
• Conclusion
2
www.tetrahedron.in +918984189814
 Introduction

*Lean Manufacturing is a systematic approach to minimizing

waste within a manufacturing system without sacrificing
productivity.

*It emphasizes efficiency, quality, and customer value,

shaping the competitive landscape of the manufacturing
industry.

*Lean production is a robust worldwide methodology that

enhances operational efficiency and competitiveness.
www.tetrahedron.in +918984189814 3
 What is Lean Manufacturing?

Lean Manufacturing is a methodology that focuses on

reducing waste and improving manufacturing processes.

It aims to create more value for customers with fewer

resources by optimizing production flow and eliminating
inefficiencies.

www.tetrahedron.in +918984189814 4
 Where It Comes From
The roots of Lean Manufacturing can be traced back to the post-
World War II era in Japan. Toyota Motor Corporation, led by
Taiichi Ohno and Eiji Toyoda, developed the Toyota Production
System (TPS), emphasizing efficiency and waste reduction.

TPS became the foundation of Lean Manufacturing, influencing

countless industries beyond automotive production.

This historical context is crucial to understanding how Lean

Manufacturing principles were formulated and refined over
decades.

www.tetrahedron.in +918984189814
 Who Invented Lean Manufacturing

Lean Manufacturing was developed by Toyota engineers

Taiichi Ohno and Eiji Toyoda, evolving from the Toyota
Production System (TPS).

The term "Lean" was popularized by James Womack,

Daniel Jones, and Daniel Roos in their 1990 book "The
Machine That Changed the World."

6
www.tetrahedron.in +918984189814
 Purpose of Lean Manufacturing

The primary purpose of Lean Manufacturing is to enhance

customer value by systematically eliminating waste.

Lean principles aim to streamline production processes,

improve product quality, reduce lead times, and lower costs.

7
www.tetrahedron.in +918984189814
 How Lean Manufacturing Works

Lean Manufacturing identifies and eliminates waste in all

forms—overproduction, waiting, transportation,
overprocessing, excess inventory, unnecessary motion, defects,
and underutilized talent.

It relies on continuous improvement, where small,

incremental changes are made regularly to enhance efficiency
and effectiveness.

8
www.tetrahedron.in +918984189814
 5 Principles of Lean Manufacturing

1. Value: Define what is valuable to the customer and focus

on it. Understanding customer needs and preferences is
crucial for identifying value.
2.Value Stream: Map out all steps in the value stream and
eliminate non-value-added steps. This helps visualize the
entire process and identify areas for improvement.
3.Flow: Ensure the product flows smoothly through the
production process without delays. Creating a smooth flow
reduces bottlenecks and inefficiencies, ensuring that each
step in the process is optimally aligned.
4.Pull: Produce only what is needed when needed in
response to customer demand.
5.Perfection: Continuously strive for perfection by
identifying and removing the root causes of problems.
Lean Manufacturing Excellence 9
5 Process Flow of Lean Manufacturing
Principles

www.tetrahedron.in +918984189814
 8 Wastes of Lean Manufacturing

⮚ Overproduction
⮚ Waiting
⮚ Transportation
⮚ Overprocessing
⮚ Inventory
⮚ Motion
⮚ Defects
⮚ Underutilized Talent

11
www.tetrahedron.in +918984189814
 Lean Tools and Concepts
• 5S: Sort, Set in order, Shine, Standardize, Sustain. This tool
enhances workplace organization by creating a clean, orderly,
safe work environment.
• Kaizen: Continuous improvement. It encourages small,
incremental changes to improve processes continually, fostering
a culture of ongoing enhancement.
• Kanban: Visual scheduling system. It helps manage workflow
and improve efficiency by ensuring work is pulled through the
production process as needed, reducing bottlenecks.
• Value Stream Mapping: Visual tool to analyze current, future
states of processes. It helps identify waste and opportunities for
improvement by mapping out the entire production process.
• Just-In-Time (JIT): Producing only what is needed when it is
required. JIT helps reduce inventory costs and increase efficiency
12
www.tetrahedron.in +918984189814
Complete list of Lean Tools and
Concepts

www.tetrahedron.in +918984189814
 How Can it Be Implemented

Implementing Lean Manufacturing involves several steps:

1. Assessment
2. Training
3. Pilot Projects
4. Full Implementation
5. Continuous Improvement

14
www.tetrahedron.in +918984189814
 Challenges in Lean
Implementation
1. Resistance to Change: Employees may resist new
ways of working. Change can be difficult, and addressing
concerns and involving employees in the process is
essential.

2. Insufficient Training: Lack of understanding of Lean

principles. Proper training is crucial for successful
implementation. Providing comprehensive training
programs can help build Lean capabilities.

3. Inconsistent Application: Consistency is critical to

achieving long-term success with Lean Manufacturing.
Developing standard procedures and ensuring adherence to
Lean practices can help maintain consistency.
15
www.tetrahedron.in +918984189814
 Solutions in Lean Implementation

1. Comprehensive Training: Provide ongoing education

on Lean tools and concepts. Continuous training helps
ensure that everyone can apply Lean principles effectively.

2. Standardization: Develop standard procedures to

maintain consistency. Standardization helps ensure that
Lean practices are applied consistently across the
organization.

3. Long-term Perspective: Focus on sustainable, long-

term improvements. Maintaining a long-term perspective
helps ensure that Lean Manufacturing delivers lasting
benefits.
16
www.tetrahedron.in +918984189814
 Future of Lean Manufacturing

• Lean Manufacturing will also increasingly focus on sustainability,

addressing environmental concerns by reducing waste and energy
consumption.
• The circular economy concept, which emphasizes resource
efficiency and waste minimization, aligns well with Lean
principles and will shape the future of Lean Manufacturing. As
organizations strive to reduce their environmental footprint, Lean
practices will be critical in achieving sustainability goals.
• Additionally, the rise of Industry 4.0, characterized by smart
factories and interconnected systems, will further enhance the
capabilities of Lean Manufacturing.

17
www.tetrahedron.in +918984189814
 Recap of Key Points

▪ Lean Manufacturing is about minimizing waste and

maximizing value.
▪ Originated from Toyota's Production System. - Focuses on
continuous improvement and efficiency.
▪ Involves principles like value, flow, pull, and perfection.
▪ Applicable across various industries for sustainable growth
and success.

18
www.tetrahedron.in +918984189814
 BENEFITS OF TQM:

• Increased Efficiency
• Improved Quality
• Cost Reduction
• Enhanced Flexibility
• Employee Engagement
• Customer Satisfaction

19
www.tetrahedron.in +918984189814
 Importance of Lean in Manufacturing
Industry
Lean Manufacturing is crucial in the manufacturing
industry as it enhances efficiency, reduces waste, and
improves product quality. By streamlining processes and
emphasizing continuous improvement, Lean helps
companies respond quickly to market demands, reduce
costs, and maintain a competitive edge in a rapidly evolving
market.

20
www.tetrahedron.in +918984189814
 Advantages of tqm

• Enhanced Efficiency: Streamlined processes and waste

reduction accelerate production.

• Higher Quality: Continuous improvement practices lead

to better product quality.

• Cost Savings: Reduced inventory and optimized

resources lower operational expenses.

www.tetrahedron.in +918984189814 21
 Disadvantages of tqm

• Employee Stress: Continuous pressure to improve and

eliminate waste can lead to high stress and burnout among
workers.

• Supply Chain Vulnerability: Lean's minimal inventory

approach can cause disruptions if supply chain issues arise.

www.tetrahedron.in +918984189814 22
 Models of Lean Production

www.tetrahedron.in +918984189814 23
 BENEFITS OF APPLY LEAN IN
MANUFACTURING INDUSTRY
• Increased Efficiency: Lean reduces waste, streamlines
processes, and improves workflow, leading to faster production
times.
• Improved Quality: Emphasis on continuous improvement and
defect prevention enhances product quality.
• Cost Reduction: Lower inventory levels and optimized resource
use significantly cut operational costs.

www.tetrahedron.in +918984189814 24
 CONCLUSION

Lean Manufacturing implementation remains a pivotal strategy in modern

production, focusing on waste reduction and value creation. Organizations
can significantly enhance their efficiency and competitiveness by
understanding their principles, tools, and implementation strategies.

Lean Manufacturing is a set of tools and a comprehensive philosophy guiding

continuous improvement and operational excellence.

www.tetrahedron.in +918984189814 25
 Thank You!

Contact Us: [email protected]

Visit Our website: www.tetrahedron.in

Call/Whatsapp: +918984189814

Facebook Linkedin
Instagram
26