Lean Processes = Lean Manufacturing and Lean Services
Lean processes are applied to manufacturing and services equally well. Lean is a process philosophy that guides a practical approach to continuous performance improvement that has delivered huge benefits to many companies.
Historically, firms have been organized in functional silos with poorly defined processes. Successes at world-class organizations have defined new models of performance and operational efficiency. One solution has been the development of Lean, which is intolerant of waste.
Those early adoption companies have evolved a new methodology that sees Lean embedded in the Six Sigma initiative.
What are Lean Processes?
Lean manufacturing and Lean services are based on the notion that wherever work is done, whether operational or transactional in nature, waste is being generated. By applying Lean tools and techniques, an organization begins to manage its processes to an optimal level. By focusing on the identification and elimination of waste, processes flow continuously.
Lean manufacturing and Lean services encompass less analysis such as Six Sigma DMAIC or DFSS and rely greatly on a team-based approach. This facilitates a quick understanding of the process, identification, and elimination of waste. The outcome is an effective and efficient running process and ultimately a more profitable business.
Lean is a flexible methodology that can be used at all levels within and around an organization. It is not a long, complicated methodology based on statistical analysis.
The Essential Lean Processes Principles
The 5 principles for Lean processes are:
- Specify value by product or service from a business perspective.
- Identify the value stream for each product and service.
- Make value flow without interruption.
- Let the customer pull value from the supplier.
- Strive for perfection.
Lean Processes objectives are set top-down:
- Deliver services that customers ask for, when and where they need them.
- Manage the life-cycle costs of products and services.
- Deviler best possible appropriate quality through innovation.
Lean Processes Excellence is delivered bottom-up
- nnecessary effort does not add value to customers.
- Unleveled or unevenness is waste resulting from time, quality, and demand Variation.
- Overburdened resources (e.g. employees, equipment etc.) results from inadequate planning. and create inefficiency.
Lean Processes are sustained when everyone’s efforts are synchronized
- The bottom-up perspective employes tools and techniques to optimize processes.
- The top-down perspective aligns process optimizations effort to overall business performance objectives.
Lean Processes Tools & Techniques
Some of the typical Lean Manufacturing and Lean Services tools and techniques employed include:
- Five S
- Theory of Constraints
- Continuous Flow
- ob / Load Leveling
- Takt time
- Value Stream Mapping – current state Process mapping.
- Analysis Value Stream Mapping – Future state Continuous Improvement Implement
- Baseline data
- Spaghetti Charting
- Time Study Analysis
- Production Capacity
- validate and standardize
- Visual Workplace
- and more