Lean manufacturing aims to reduce waste by focusing on adding value for the end customer. Implementing lean practices requires commitment and can involve significant change. The 5S program is a common starting point, but every business is different and should look for further opportunities for improvement.
Lean manufacturing is the practice of severely limiting the resources wasted in manufacturing and other fields under the assumption that anything that does not directly lead to the end-user value of a product or service is waste. When planning a lean manufacturing implementation program, it is very important to try to look at expenses from the customer’s point of view. If an expense brings no value to the end customer, it should be considered a target for implementing lean manufacturing and should be removed or streamlined. Areas that should be looked into for implementing lean manufacturing include transportation costs and inventory management, overproduction, organization, and any time spent on hold – problems in all of these areas can lead to waste, which contribute in any way to the value of the product used by the end customer.
One of the most important prerequisites for implementing lean manufacturing is commitment. If decision makers and production managers fail to consistently implement lean manufacturing practices, it is likely that the entire lean implementation drive will fail. In many cases, the introduction of lean manufacturing practices can drastically alter the company’s previous practices and traditions and can even result in the reduction of some jobs. Change can be positive, but the transition is unlikely to be painless, so commitment is needed.
A commonly used starting point for implementing lean manufacturing is the “5S” program, which focuses on dispatch; straightening or putting in order; sweep; standardization; and uphold discipline. Sorting involves identifying and eliminating all unnecessary resources and ensuring that all required resources are easy to locate and use. Straightening means ensuring everything is placed in the workplace according to who needs it and where it needs it, so no one has to waste time and effort locating resources, and sweeping refers to policies that ensure cleanliness and general workplace order. Standardizing is about finding and universally implementing the most efficient way to complete a given task, and sustaining discipline is about ensuring that everyone follows the new policies and doesn’t revert to old, less efficient business practices.
There are many other programs for implementing lean manufacturing, but they all tend to focus on the same general ideas: eliminating the unnecessary and simplifying every process. Such programs can serve as a good starting point for implementing lean manufacturing, but it’s important to remember that every business is different, and what works for one may not work for another. Following a program like “5S” can eliminate a great deal of waste and provide you with a good start, but for the best implementation of lean manufacturing processes, you still need to look for more opportunities for improvement.
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