What Is Lean Manufacturing?

What is lean manufacturing is a common question these days, but the businesses of yesteryears have missed out on this. Lean manufacturing process would have ideally suited Henry Ford when he implemented assembly-line production in his Detroit factory, had wastage problem not bothered him much. But with modern day Henry Fords, it does a lot. Wastage at the inventory level, at assembly line level, at interchangeable worker level, and many more strategic points, are the biggest source of headache for manufacturers the world over. The Lean manufacturing process tries to do away with wastage at all level, making productivity more profitable. And that is precisely why, understanding what is lean manufacturing is so important. In practical terms, this may be considered somewhat similar to cooking lean pork where superficial fat is eliminated before the actual cooking takes place.

Ingeniously designed by Sakichi Toyoda and better known as Toyota Production System, this process is basically a Japanese production methodology that has currently attracted the attention of most manufacturers. It includes, among other innovative techniques, placing small inventory of stockpiles in pre-determined spots around the assembly-line, instead of storing them in centralized warehouses that are often located in a different building. Known as Kanban, the use of these smaller stockpiles appreciably brings down the wastage factor, thereby lowering down the overall production cost, while enhancing productivity.

Apart from elimination of wastage during the manufacturing process, the process also aims at providing optimum standards by adopting a method in which each component is subjected to rigorous tests, immediately after it is produced. And in case any fault is found, the production line is stopped forthwith, thus preventing overall loss. Those who try to understand what is lean manufacturing and practice it, often compared this to the TQM (Total Quality Management) technique since in both of these, more emphasis is given to workmen stationed at the assembly line as they are closest to the operational level, and are so the best judges to determine the right method of production.

It also emphasizes on smaller inventory directly at the work-site instead of hoarding large stockpiles in distant warehouses. Here, suppliers are instructed to deliver smaller lots and that too daily, a system that does not warranty high machining hours. This saves money on inventory cost, while abolishing all other wasteful operations of conventional manufacturing process.

If you want to know what is lean manufacturing and its advantages, then it would be, lesser lead times, lower equipment usage and reduced set-up times, lesser inventory control – all leading to increased profit.