Lean Manufacturing Principles

Identify Value Map Value Stream Create Flow Establish Pull Seek Perfection

[1] Identify Value:

Examples of Lean Principles:

[2] Map Value Stream [VSM Study]:

[3] Create Flow:

[4] Establish Pull:

[5] Seek Perfection:





👉 Also Read:

ISO 9001-2015 (Quality Management System) 2.(Quality Management System)





→ Five FundamentalPrinciples are mentioned below:→ The Lean approach begins with a detailed understanding of the value assigned to products or services by the customer.→ This determines what the customer will pay.→ Establishing worth allows organizations to create a top to the bottom target price.→ The cost to produce the products and services is then determined.→ The organization focuses on eliminating waste so that it can meet the customer's expectations.→ As an organization, we must have to give importance to our customer’s needs for a specific product.→ What is the timeline for manufacturing and delivery?→ What is the price point?→ What are other important requirements or expectations that must be met?→ The Value stream is the product’s entire life-cycle from the raw materials to the customer’s use and also disposal of the product.→ In order to eliminate waste, there must be an accurate and complete understanding of the operation.→ Processes are examined to determine what worth is added by steps, materials, features, and movement.→ Steps, materials, features, and movements that do not add worth are eliminated.→ Once the end goal has been determined, the next step is mapping all the steps and processes involved in taking a specific product from raw materials and delivering the final product to the customer.→ VSM Study is a simple but eye-opening experience that identifies all the actions that take a product or service through any sequence of operations.→ The idea is to draw, on one page, a "map" of the flow of material/product through the process.→ The goal is to identify every step that does not create worth and then find ways to eliminate those wasteful steps.is sometimes referred to as process re-engineering. Ultimately this exercise also results in a better understanding of the entire business operation.→ Understanding flow is essential to the elimination of→ Create flow is about creating a value chain with no interruption in the production process.→ After the waste has been removed from the process, the next step is to be sure the remaining steps flow smoothly with no interruptions, delays, or bottlenecks.→ Make the worth creating steps occur in a tight sequence so that the product or service will flow smoothly toward the customer.→ However, studies show that this will also lead to huge gains in productivity and efficiency, sometimes as high as 50-percent improvement or more→ The lean principle of pull helps ensure flow by making sure that nothing is made ahead of time, building up work-in-process inventory.→ Rather than using the traditional American manufacturing approach of pushing work through based on a forecast and schedule, the pull approach that nothing is made until the customer orders it.→ This requires a great deal of flexibility and short design to delivery cycle times.→ It also requires an efficient way of communicating what is needed for each step.→ The Pull system makes easier to deliver products as needed, as in “just in time” manufacturing or delivery.→ This means the customer can “pull” the product from you as needed (often in weeks, instead of months).→ As a result, products don’t need to be built in advance or materials stockpiled, creating an expensive inventory that needs to be managed, saving money for both the manufacturer/provider and the customer.→ The march toward perfect process happens step by step as continuous improvements and implementing preventive actions on root causes of quality problems and production waste.→ Experts often say that a process is not truly lean until it has been through VSM at least half a dozen times.→ Continuously dig deeper, measure more, and change more in the process for achieving the perfect lean process.→ Accomplishing Steps 1-4 is a great start, but the fifth step of Perfection is the most important→ Making lean thinking andas a part of your corporate culture.→ It is important to remember that lean is not a static system it requires constant effort and vigilance to perfect.→ Every employee shall be involved in the implementation activity.