Lean Manufacturing Processes

Writen by Kent Pinkerton

There are several processes that organizations apply to implement as a part of their lean manufacturing initiative. Some of the most famous ones are discussed below.

Kaizen Rapid Improvement Process:

The basic idea of Kaizen or continual improvement is that small, incremental changes routinely applied and sustained over a long period result in significant improvements. The focus of Kaizen is on eliminating waste in the targeted systems and processes of an organization in order to improve productivity and achieve sustained continual improvement. One of the important aspects of the Kaizen strategy is to involve workers from multiple functions and levels in the organization in working together to address a problem or improve a particular process.

Just-in-time Production:

Just-in-time production (JIT) helps reduce inventory and work in process (WIP). JIT enables a company to produce the products that customers want, when they want them, in the amount they want. JIT techniques spread production evenly over time to foster a smooth flow between processes. Varying the mix of products produced on a single line provides an effective means for producing the desired production mix in a smooth manner. Many companies implementing JIT signal their suppliers, using computers or delivery of empty containers, to supply more of a particular component when they are needed. The end result of JIT production is typically a significant reduction in waste associated with unnecessary inventory, WIP, packaging, and overproduction.

Six-Sigma:

Six-Sigma draws on well-established statistical quality control techniques and data analysis methods. The term ?sigma? is a Greek alphabet letter that is commonly used to describe variability. A sigma quality level is an indicator of how often defects are likely to occur in processes, parts, or products. A Six-Sigma quality level equates to approximately 3.4 defects per million opportunities, representing high quality and minimal process variability. Six-Sigma consists of a set of structured, data-driven methods for the systematic analysis of processes to reduce process variation. These methods are used to support and guide organizational continual improvement activities.

Given the competition faced by companies and the external business environment, it is becoming increasingly important for companies to adopt lean manufacturing processes to stay competitive.

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