Lean Manufacturing Principles to Know for Intro to Industrial Engineering

Lean Manufacturing Principles focus on maximizing value while minimizing waste in production processes. These concepts, like Value Stream Mapping and Just-in-Time production, enhance efficiency and responsiveness, connecting directly to global supply operations and strategic cost management.

1. Value Stream Mapping

   • Visual representation of the flow of materials and information in a process.
   • Identifies value-added and non-value-added activities.
   • Helps in pinpointing areas for improvement and waste reduction.

2. Just-in-Time (JIT) Production

   • Produces only what is needed, when it is needed, and in the amount needed.
   • Reduces inventory costs and minimizes waste.
   • Enhances flexibility and responsiveness to customer demand.

3. Continuous Flow

   • Ensures a smooth and uninterrupted flow of materials through the production process.
   • Reduces lead times and increases efficiency.
   • Minimizes work-in-progress inventory.

4. Pull System

   • Production is driven by actual customer demand rather than forecasts.
   • Reduces overproduction and excess inventory.
   • Encourages a more responsive and adaptive production environment.

5. Kaizen (Continuous Improvement)

   • Focuses on small, incremental changes to improve processes.
   • Involves all employees in identifying and solving problems.
   • Aims for ongoing improvement in quality, efficiency, and productivity.

6. 5S (Sort, Set in Order, Shine, Standardize, Sustain)

   • A workplace organization method to improve efficiency and safety.
   • Sort: Eliminate unnecessary items.
   • Set in Order: Organize tools and materials for easy access.
   • Shine: Clean the workspace regularly.
   • Standardize: Establish procedures for consistency.
   • Sustain: Maintain and review standards regularly.

7. Total Productive Maintenance (TPM)

   • Aims to maximize equipment effectiveness and minimize downtime.
   • Involves all employees in maintenance activities.
   • Focuses on proactive and preventive maintenance strategies.

8. Kanban

   • A visual scheduling system that controls the flow of materials.
   • Uses cards or signals to indicate when to produce or move items.
   • Helps in managing inventory levels and reducing waste.

9. Poka-Yoke (Error-Proofing)

   • Techniques designed to prevent errors in manufacturing processes.
   • Aims to eliminate defects by making it impossible to make mistakes.
   • Enhances product quality and reduces rework.

10. Standardized Work

    • Establishes consistent methods for performing tasks.
    • Ensures quality and efficiency by documenting best practices.
    • Serves as a baseline for continuous improvement efforts.

11. Takt Time

    • The maximum allowable time to produce a product to meet customer demand.
    • Helps in balancing production rates and workloads.
    • Ensures that production aligns with customer needs.

12. Heijunka (Production Leveling)

    • Aims to smooth out production schedules to reduce variability.
    • Balances workload across different processes and time periods.
    • Enhances efficiency and reduces lead times.

13. Jidoka (Autonomation)

    • Automation with a human touch; machines stop automatically when a problem occurs.
    • Empowers workers to identify and solve issues immediately.
    • Enhances product quality and reduces defects.

14. Muda, Mura, Muri (Waste, Unevenness, Overburden)

    • Muda: Any activity that does not add value to the product.
    • Mura: Variability in processes that can lead to inefficiencies.
    • Muri: Overburdening people or equipment, leading to stress and breakdowns.

15. Visual Management

    • Uses visual cues to communicate information and status in the workplace.
    • Enhances understanding and awareness of processes and performance.
    • Facilitates quick decision-making and problem-solving.