{"id":1214,"date":"2018-04-10T13:44:40","date_gmt":"2018-04-10T13:44:40","guid":{"rendered":"https:\/\/www.mrpeasy.com\/blog\/?p=1214"},"modified":"2022-12-15T13:16:38","modified_gmt":"2022-12-15T13:16:38","slug":"lean-manufacturing","status":"publish","type":"post","link":"https:\/\/www.mrpeasy.com\/blog\/lean-manufacturing\/","title":{"rendered":"Lean Manufacturing Practices that can Help Improve Your Manufacturing Processes"},"content":{"rendered":"\n<div class=\"wp-block-image\"><figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"980\" height=\"490\" src=\"https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2022\/12\/Lean-manufacturing.webp\" alt=\"\" class=\"wp-image-12695\" srcset=\"https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2022\/12\/Lean-manufacturing.webp 980w, https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2022\/12\/Lean-manufacturing-300x150.webp 300w, https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2022\/12\/Lean-manufacturing-768x384.webp 768w\" sizes=\"auto, (max-width: 980px) 100vw, 980px\" \/><\/figure><\/div>\n\n\n\n<p><em>You can also listen to this article:<\/em><\/p>\n\n\n\n<iframe loading=\"lazy\" title=\"Lean Manufacturing Practices that can Help Improve Your Manufacturing Processes\" height=\"122\" width=\"100%\" style=\"border: none;\" scrolling=\"no\" data-name=\"pb-iframe-player\" src=\"https:\/\/www.podbean.com\/media\/player\/j64gf-e12d73?from=pb6admin&amp;download=1&amp;version=1&amp;auto=0&amp;share=1&amp;download=1&amp;rtl=0&amp;fonts=Helvetica&amp;skin=1&amp;pfauth=&amp;btn-skin=103\"><\/iframe>\n\n\n\n<p>Any manufacturer understands the importance of practices that add value to their operation, and that\u2019s exactly what\u2019s at the core of lean manufacturing.<\/p>\n\n\n\n<!--more-->\n\n\n\n<p>The <a href=\"https:\/\/www.mrpeasy.com\/blog\/what-is-lean-manufacturing\/\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\">lean philosophy<\/a> revolves around one very simple idea: eliminating all waste across the manufacturing process. Waste can be defined as any production activity that adds no value from the customer perspective, and you may be surprised to know these can amount to up to 60% of the production activities in a typical manufacturing operation.<\/p>\n\n\n\n<p>As waste comes in many forms, like lack of flow between stages of production, overproduction, excess of labour motion, defects, and more; most operations also have proportional improvement opportunities through lean manufacturing practices and techniques.<\/p>\n\n\n\n<p>Although in general they may seem abstract, overly-complicated, or even costly, the correct execution and effective application of these translates into processes that affect the overall operation to increase quality, safety, and labour morale. All of this, while keeping costs and lead times as minimal as possible. Eventually, consistency in these practices will turn into profit.<\/p>\n\n\n\n<p>With that in mind, here\u2019s an introduction to some practices that will help you get started in the never-ending commitment of improving your manufacturing processes.<\/p>\n\n\n\n<div id=\"ez-toc-container\" class=\"ez-toc-v2_0_80 counter-hierarchy ez-toc-counter ez-toc-custom ez-toc-container-direction\">\n<div class=\"ez-toc-title-container\">\n<p class=\"ez-toc-title\" style=\"cursor:inherit\">Table of Contents<\/p>\n<span class=\"ez-toc-title-toggle\"><a href=\"#\" class=\"ez-toc-pull-right ez-toc-btn ez-toc-btn-xs ez-toc-btn-default ez-toc-toggle\" aria-label=\"Toggle Table of Content\"><span class=\"ez-toc-js-icon-con\"><span class=\"\"><span class=\"eztoc-hide\" style=\"display:none;\">Toggle<\/span><span class=\"ez-toc-icon-toggle-span\"><svg style=\"fill: #343333;color:#343333\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" class=\"list-377408\" width=\"20px\" height=\"20px\" viewBox=\"0 0 24 24\" fill=\"none\"><path d=\"M6 6H4v2h2V6zm14 0H8v2h12V6zM4 11h2v2H4v-2zm16 0H8v2h12v-2zM4 16h2v2H4v-2zm16 0H8v2h12v-2z\" fill=\"currentColor\"><\/path><\/svg><svg style=\"fill: #343333;color:#343333\" class=\"arrow-unsorted-368013\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"10px\" height=\"10px\" viewBox=\"0 0 24 24\" version=\"1.2\" baseProfile=\"tiny\"><path d=\"M18.2 9.3l-6.2-6.3-6.2 6.3c-.2.2-.3.4-.3.7s.1.5.3.7c.2.2.4.3.7.3h11c.3 0 .5-.1.7-.3.2-.2.3-.5.3-.7s-.1-.5-.3-.7zM5.8 14.7l6.2 6.3 6.2-6.3c.2-.2.3-.5.3-.7s-.1-.5-.3-.7c-.2-.2-.4-.3-.7-.3h-11c-.3 0-.5.1-.7.3-.2.2-.3.5-.3.7s.1.5.3.7z\"\/><\/svg><\/span><\/span><\/span><\/a><\/span><\/div>\n<nav><ul class='ez-toc-list ez-toc-list-level-1 ' ><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-1\" href=\"https:\/\/www.mrpeasy.com\/blog\/lean-manufacturing\/#Minimizing_waste\" >Minimizing waste<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-2\" href=\"https:\/\/www.mrpeasy.com\/blog\/lean-manufacturing\/#Constant_improvement\" >Constant improvement<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-3\" href=\"https:\/\/www.mrpeasy.com\/blog\/lean-manufacturing\/#Optimized_production_flow\" >Optimized production flow<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-4\" href=\"https:\/\/www.mrpeasy.com\/blog\/lean-manufacturing\/#Streamlined_sales_customer_service\" >Streamlined sales &amp; customer service<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-5\" href=\"https:\/\/www.mrpeasy.com\/blog\/lean-manufacturing\/#Seamless_collaboration\" >Seamless collaboration<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-6\" href=\"https:\/\/www.mrpeasy.com\/blog\/lean-manufacturing\/#Final_Thoughts_on_Lean_Manufacturing_Processes\" >Final Thoughts on Lean Manufacturing Processes<\/a><\/li><\/ul><\/nav><\/div>\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Minimizing_waste\"><\/span>Minimizing waste<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>Minimizing and, if possible, eliminating all waste is the general purpose of the lean methodology and, as stated before, regardless of the phase of the process, waste can exist at any level associated with manufacturing. To effectively identify waste, it\u2019s best to think of it as anything that:<\/p>\n\n\n\n<ul class=\"wp-block-list\"><li>Doesn\u2019t serve a specific customer requirement<\/li><li>Can be done spending less resources<\/li><\/ul>\n\n\n\n<p>It\u2019s critical to clearly <a href=\"https:\/\/www.cmtc.com\/blog\/identifying-waste-in-manufacturing\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\">identify waste<\/a>, before moving forward with the next steps.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Constant_improvement\"><\/span>Constant improvement<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>The implementation of a lean methodology is not something that can ever be finished. The most common thing to do when engaging a lean transformation is to set initial goals, but it is crucial to keep in mind that once achieved you\u2019ll need to aim for new ones. There will always be something to improve, more and new ways to boost efficiency, more ways to refine processes, more ways to eliminate waste and to get the most out of your lean manufacturing investments.<\/p>\n\n\n\n<p>If you\u2019d like to research more about implementing lean techniques in your facility, have a look at this paper on lean implementation.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Optimized_production_flow\"><\/span>Optimized production flow<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>Although lean principles and concepts should be applied throughout the whole organization and not just the manufacturing process, it\u2019s more often employed in terms of the production plant. In the best of examples, this looks like a seemingly frictionless work flow throughout every process, and the transitions in between, with only the absolute minimum delays, inventory, handling, downtime, rework, and scrap.<\/p>\n\n\n\n<p>With a stream mapping feature, <a href=\"https:\/\/www.mrpeasy.com\/\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\">MRP<\/a> (Material Resource Planning) software can create a model to display how materials and data flow through a production process. This is an incredibly valuable asset in the process of identification of bottlenecks and other improvement opportunities overall.<\/p>\n\n\n\n<p>MRP software can be used for monitoring the time it takes for materials to get to the dock and to be dispatched as a complete product, a metric that is crucial in the assessment of lean opportunities and improvements. You can find out more about the benefits of an MRP system in your manufacturing operation in this <a href=\"https:\/\/www.mrpeasy.com\/blog\/benefits-of-mrp\/\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\">article.<\/a><\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Streamlined_sales_customer_service\"><\/span>Streamlined sales &amp; customer service<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>Customer service should be at the heart of any organization and, as such, lean practices need to be implemented not only to minimize and eliminate waste in the product-creation processes, but also to improve customer service. Once you remove waste from customer service processes, you\u2019ll also get rid of inconveniences, delays, and costs, which will inevitably result in a streamlined process that\u2019ll make the overall customer experience more rewarding.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Seamless_collaboration\"><\/span>Seamless collaboration<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>Lean practices and principles are meant to be used just as much within the manufacturing space as beyond it. With a proper demand forecast, production takes on a new and more efficient dimension, where the manufacturer is able to plan, produce and ultimately provide what the customers really want, and how they want it, while keeping unnecessary process steps and inventory at a minimum. A better forecast is achieved by getting lots of relevant information from your sales department, agents, distributors, and most importantly, <em>customers<\/em>. The knowledge to interpret this data also resides with them.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Final_Thoughts_on_Lean_Manufacturing_Processes\"><\/span>Final Thoughts on Lean Manufacturing Processes<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>To stay competitive in the manufacturing sector, it\u2019s critical that you continually improve your processes to help maximize your profitability. Using lean processes, measurement, and methodologies \u2013 you\u2019d be surprised at how much waste can be taken out of your operation to help you stay ahead.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>You can also listen to this article: Any manufacturer understands the importance of practices that add value to their operation, and that\u2019s exactly what\u2019s at the core of lean manufacturing.<\/p>\n","protected":false},"author":1,"featured_media":12695,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[94,93],"tags":[37],"class_list":["post-1214","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-tips","category-production-planning","tag-lean-manufacturing"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v26.7 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Lean Manufacturing 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