Service Areas  |  Lean Manufacturing

The Lean Solution

Many of our clients have heard of the lean manufacturing approach through articles, books, seminars, or professional associations. But as the authors of Lean Thinking report, most readers want to know, “Just how do you do it?” If you have not already read Lean Thinking, I strongly recommend it. We have found through interaction with clients that actual application experience is their preferred learning method. Therefore, this article is focused on our experiences and recent lean case studies.

To begin, you need to establish a process foundation and an outline for Lean Thinking. An easy reference to Lean Thinking is “No Waste – No Inventory.” Now that’s pretty easy to remember and say, but as stated earlier, “Just how do you do it?”

There are five critical elements that define the process of Lean Thinking.

Value – Created by the producer but can only be defined by the customer.

Value Stream – The set of all specific actions required to bring a specific product through three critical management tasks: problem solving, information management, and the physical transformation process.

Flow – Represents the efficiency by which we turn customer interest into customer satisfaction.

Pull – Let customer determine what you produce and when you produce it.

Perfection – Compete against yourself to effect continuous improvement.

CASE STUDIES

Many studies and reports highlight large companies where products can be separated to create an identifiable product stream. High volume products make it easier to identify where value and non-value added steps can be seen. However, most of our client base represents smaller companies who don’t have large product lines or products, but are real life job shops. Many do not have the volume to develop stand-alone product lines. Lean Thinking can be applied within smaller firms, and here is how!

THE ACTION PLAN

Change Agent – In all our successful applications there is an identifiable change agent. The “make something happen” agent has held different positions with different companies such as production manager, manufacturing engineer, vice president Operations, vice president Engineering, and individual company proprietor. In other words, you too can be a change agent.

Get the Knowledge – Get the knowledge through MEP. At the Institute for World Class Manufacturing offers workshops in Lean Thinking through individual courses on specific topics such as flow manufacturing, cellular manufacturing, set up reduction, change management, team development training, information technology, and others. The most successful lean applications have resulted following IWCM attendance coupled with our two-day Kaizen blitz and plant tour.

Seize the Crisis or Create One – Start with a pilot project for a process, which is in crisis, and focus all your energies toward lean solutions. Our job shop clients have been highly successful in getting started on the road to Lean Thinking following set up reduction, cellular manufacturing and Kaizen process improvement programs.

Map the Value Stream – Look at the entire Value Stream of the parts/products that travel through your processes. Document the path and timeline from inception of the order through shipment to your customer.

Flow – Focus on the process/product and begin to think in terms of lean manufacturing from when you first pick up the sales order through the transformation process, without letting go of the product until you are ready to ship. Ignore all traditional boundaries, rethink specific work practices, and eliminate all back flows.

Pull – No upstream process should produce a good until the customer asks for it. A collaboration between customers and your vendors is essential to create an efficient methodology to supply what is needed and when. The mechanics of lot sizing, container size, lead-time, and frequency of delivery is a straightforward process.

Perfection – Focus on the complete elimination of waste through radical or incremental change. While it is important to benchmark for industry or process comparisons, you should compete against yourself to attain the greatest benefit.

In conclusion, the lesson is to get started immediately with an important visible activity! Demand immediate results. And as soon as you have momentum, expand your scope.