Lean Manufacturing | A pursuit of perfection.
Lean manufacturing is a systematic approach to identifying and eliminating waste in manufacturing processes. It is based on the idea that by eliminating waste, companies can improve their efficiency, productivity, and quality. A pursuit of perfection.
The Toyota Production System (TPS) is a lean manufacturing system that was developed by Toyota Motor Corporation in the mid-20th century. TPS is based on two key principles: just-in-time (JIT) production and jidoka.
JIT production means that companies produce only the products that are needed, when they are needed. This helps to reduce inventory costs and waste. Jidoka means that workers are empowered to stop the production line if they see a problem. This helps to prevent defective products from being produced.
Toyota is so well known for lean manufacturing because it has been one of the most successful implementers of TPS. TPS has helped Toyota to become one of the most profitable and efficient automakers in the world.
Benefits:
- Reduced waste
- Increased efficiency
- Improved productivity
- Higher quality products
- Shorter lead times
- Lower costs
- Increased customer satisfaction
Lean manufacturing can be applied to any industry, not just manufacturing. It has been used successfully in a wide range of industries, including healthcare, retail, and financial services.
Lean Manufacturing Quotes
- “Today’s standardization…is the necessary foundation on which tomorrow’s improvements will be based. If you think “standardization” as the best you know today, but which is to be improved tomorrow – you get somewhere. But if you think of standards as confining, then progress stops.” ~Henry Ford
- “Many good American companies have respect for individuals, and practice Kaizen and other TPS {Toyota Production System} tools. But what is important is having all of the elements together as a system. It must be practiced every day in a very consistent manner–not in spurts–in a concrete way on the shop floor.” ~Fujio Cho, President, Toyota Motor Corporation
- “To be competitive, we have to look for every opportunity to improve efficiencies and productivity while increasing quality. Lean manufacturing principles have improved every aspect of our processes.” ~Cynthia Fanning
- “If we reduce batch sizes by half, we also reduce by half the time it will take to process a batch. That means we reduce queue and wait by half as well. Reduce those by half, and we reduce by about half the total time parts spend in the plant. Reduce the time parts spend in the plant and our total lead time condenses. And with faster turn-around on orders, customers get their orders faster.” ~Eliyahu M. Goldratt, The Goal
