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Lean Manufacturing is a business concept that focuses on increasing efficiency and productivity in the processes of manufacturing by reducing or eliminating wastage or ‘muda’ in Japanese. This is done by minimising the time and resources used. Also known as Lean Production, Special emphasis is on elimination of wastage of all types. Lean manufacturing process is a mix of different management philosophies, aimed at taking the operations level to the highest efficient level.
The origin of the lean manufacturing process is traced to Japan, with specific reference to early years of Toyota, between the late 1980s to the early 1090s. To increase profit and improve sales, Eiji Toyoda set on a journey to improvise Toyota’s manufacturing processes. He collaborated with Taiichi Ōno for developing Toyota Production System, a compilation of lean manufacturing tools. The tools were later highlighted in ‘Lean Solutions’, a book published by James Womack’s and Daniel Jones. They went on to identify the five principles of lean manufacturing.
There are five principles of lean manufacturing, as highlighted by Womack and Jones. These principles, centring around Toyota’s success, assist businesses in creating products keeping in mind what customers want.
The primary elements of lean manufacturing are as follows:
When we talk about 'waste' in lean manufacturing, it refers to the unnecessary expenditure of resources that fails to add value for a consumer. Generally, there are seven wastes in lean manufacturing:
Philosophies of businesses that form part of lean manufacturing include:
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