LEAN PRODUCTION: THE 5 BASIC PRINCIPLES OF THE LEAN METHOD
Some time ago we started talking about lean production, and the 5 basic principles that characterize it, in this article. Today we start again from the third principle, to go to the end, at least for the time being, with this topic.
3. Lean thinking: bringing everything into a value stream
After removing waste from the value stream it is necessary to apply the principle of continuous flow of production. In the lean production context, the concept of “flow” means that production takes place continuously, that is, it “flows” without interruption. The application of this principle is contrasted, for example, by buffer stocks and temporary storage, which must be avoided.
The 7 Muda, i.e., types of waste, also include high inventories and avoidable waiting times. To avoid them, it is necessary to synchronize processes with each other by adapting them to the pace of the customer. Improving production based on the
4. Efficient material flow due to the pull principle
Compared with the classical push principle, which is based on a sales forecast, the pull principle is oriented to actual customer demand. Its advantages are especially clear if we first briefly analyze the disadvantages of the push principle. Since the push principle is based on a forecast, production has already been carried out when the customer’s order arrives at the company. Although employees are always optimally employed, the disadvantages are far greater: because of high inventories, spacious warehouses are also required, which, from a lean production point of view, is wasteful.
This often results in a condition of overproduction, thus another form of waste according to the principles of the lean manufacturing method. Last but not least, the continuous flow of materials is interrupted by constant warehousing, picking and temporary storage activities. It is therefore apparent that with the push principle, cycle time reduction cannot be achieved. The primary goal of lean manufacturing cannot, therefore, be achieved.
“Compared with the push principle, a decisive advantage of the pull principle is that by designing production with short set-up times, several product variants can be produced in a single production line.”
The pull principle, on the other hand, is the exact opposite, because demand drives production: each product is manufactured only after the customer’s order arrives. Compared to the push principle, a decisive advantage of the pull principle is that by designing production with short set-up times, different product variants can be produced in a single production line. As a result, lead times are shorter and spacious warehouses for components and finished products are no longer required.
The following are the decisive advantages of the pull principle of lean production:
- small lots
- elimination of overproduction
- Continuous flow of materials, no interruption due to storage
- shorter average delivery time
- Significantly less storage area and therefore less space consumption
5. Kaizen or continuous improvement process (PMC)
Those who inquire about lean principles invariably come across Kaizen. Although it is certainly true that Kaizen plays a key role in so-called lean production., a distinction needs to be made. Too often, in fact, the differences between Kaizen and continuous improvement process (CIP) are not properly considered: these two principles are not identical. The Kaizen is a traditional way of thinking in Japanese culture according to which everything in life can be improved bit by bit. This mindset is accompanied by a positive attitude that accepts challenges and proactively seeks solutions.
“The result is a never-ending quest for perfection. After all, the essence of Kaizen is encapsulated in its name: “kai” means “change” and “zen” means “to improve.”
The continuous improvement process (CIP) referred to in lean production, on the other hand, refers only to processes in the workstation. Originally, this method covered only the work steps in industrial production. Following the success of lean production, however, general concepts such as. lean management or lean thinking.
Equipment such as transport carts, supply racks on rollers or racks with roller conveyors are created in PMC workshops. The modular lean production system lends itself to this purpose. The modular lean production system lends itself to this purpose. At the heart of the modular system is the D30 profiled tubular system, which features geometrically coupled connections that guarantee a secure seal over time and a particularly simple connection technique.
Among our companies, certainly ITEM is the one that best addresses these aspects related to workstation improvement.
Thus, today it is common practice to rely on the PMC even in office organization. In this article, however, we deal only with classical PMC in production, which is the core lean production.
To achieve continuous improvement, it is necessary to challenge all areas of production. Continuous improvement is achieved by taking small steps, as many as possible. With this in mind, the fact that the PMC mindset can only be consolidated in parallel with a
Still not satisfied and want to read more on this topic?
Find another article on lean manufacturing here on our site. Instead, you can read theoriginal article on ITEM’s website here.
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