{"id":3443,"date":"2019-07-23T12:00:20","date_gmt":"2019-07-23T12:00:20","guid":{"rendered":"https:\/\/www.mrpeasy.com\/blog\/?p=3443"},"modified":"2025-08-04T12:03:59","modified_gmt":"2025-08-04T12:03:59","slug":"what-is-lean-manufacturing","status":"publish","type":"post","link":"https:\/\/www.mrpeasy.com\/blog\/what-is-lean-manufacturing\/","title":{"rendered":"What is Lean Manufacturing?"},"content":{"rendered":"\n<p>The premise of lean manufacturing is rather simple: companies must strive to eliminate waste from the manufacturing process. <\/p>\n\n\n\n<!--more-->\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter\"><img loading=\"lazy\" decoding=\"async\" width=\"500\" height=\"300\" src=\"https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2019\/07\/What-is-lean-manufacturing.jpg\" alt=\"What-is-lean-manufacturing\" class=\"wp-image-3447\" srcset=\"https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2019\/07\/What-is-lean-manufacturing.jpg 500w, https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2019\/07\/What-is-lean-manufacturing-300x180.jpg 300w\" sizes=\"auto, (max-width: 500px) 100vw, 500px\" \/><\/figure>\n<\/div>\n\n\n<p><em>You can also listen to this article:<\/em><\/p>\n\n\n\n<iframe loading=\"lazy\" title=\"What is Lean Manufacturing?\" height=\"122\" width=\"100%\" style=\"border: none;\" scrolling=\"no\" data-name=\"pb-iframe-player\" src=\"https:\/\/www.podbean.com\/media\/player\/cupd5-c2a269?from=pb6admin&#038;download=1&#038;version=1&#038;auto=0&#038;share=1&#038;download=1&#038;rtl=0&#038;fonts=Helvetica&#038;skin=1&#038;pfauth=&#038;btn-skin=103\"><\/iframe>\n\n\n\n<p>&nbsp;<\/p>\n\n\n\n<p>In this context, waste is any activity that doesn\u2019t add value from a customer\u2019s point of view. And studies have concluded that a shocking 60% of the production activities in the average manufacturing operation are wasted and add no value for their customers.<\/p>\n\n\n\n<p>Here are some examples of waste you might be able to identify within your organization.<\/p>\n\n\n\n<p>Streamline your manufacturing operation with <a href=\"https:\/\/www.mrpeasy.com\/lean-manufacturing-software\/\">lean manufacturing software<\/a>.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">The eight most common wastes in a\nmanufacturing operation<\/h2>\n\n\n\n<p>One of the simplest methods for recognizing waste in your company is to use the acronym <strong>DOWNTIME<\/strong>. It stands for:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>D<\/strong>efects<\/li>\n\n\n\n<li><strong>O<\/strong>verproduction<\/li>\n\n\n\n<li><strong>W<\/strong>aiting<\/li>\n\n\n\n<li><strong>N<\/strong>ot utilizing talent<\/li>\n\n\n\n<li><strong>T<\/strong>ransportation<\/li>\n\n\n\n<li><strong>I<\/strong>nventory excess<\/li>\n\n\n\n<li><strong>M<\/strong>otion waste<\/li>\n\n\n\n<li><strong>E<\/strong>xcess processing<\/li>\n<\/ul>\n\n\n\n<p><strong>1. Defects: <\/strong>Mistakes typically require additional time, resources, and money to make them right. In manufacturing, a faulty product that needs to be remade is a good example. You can minimize defects with strict quality controls and standardized work plans.<\/p>\n\n\n\n<p><strong>2. Overproduction<\/strong>: Sometimes, your workers are producing for a customer who doesn\u2019t need your products right now. You\u2019re tying up working capital and production hours that could be used elsewhere in the business. Establishing reasonable workflows and having the proper procedures in place can reduce the chances of overproduction.<\/p>\n\n\n\n<p><strong>3. Waiting<\/strong>: Waiting for approvals, materials, or because of a breakdown or bottleneck is expensive. Make sure you have enough workers to prevent bottlenecks and <a href=\"https:\/\/www.mrpeasy.com\/inventory-software-manufacturing\/\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\"inventory controls (opens in a new tab)\">inventory controls<\/a> that eliminate the wait for materials.<\/p>\n\n\n\n<p><strong>4. Not using talent correctly<\/strong>: When your workers are under-utilized or not utilized at all, it leads to a lack of engagement from them. Any company can reap the benefits of higher productivity from their people by not micromanaging them, giving them adequate training, and empowering them to work independently.<\/p>\n\n\n\n<p><strong>5. Transportation<\/strong>: When manufacturing companies move things excessively, they waste time and increase their costs. Simplified processes and efficient plant layouts are just two of the ideas for combatting too much movement.<\/p>\n\n\n\n<p><strong>6. Inventory excess<\/strong>: Too much supply and insufficient demand add up to an excess of inventory. Better monitoring systems and an end to just-in-case manufacturing will trim your inventory.<\/p>\n\n\n\n<p>7. <strong>Motion waste<\/strong>: Just as with transportation, wasted motion by workers or machines adds expense\u2014but no value\u2014to your product or process. Make sure your plant layout incorporates shorter distance between stations and that it\u2019s easy for workers to reach tools that they use often.<\/p>\n\n\n\n<p><strong>8. Excess processing<\/strong>: Even the best companies can be stuck with several versions of the same task or require more reports than are necessary. These extra steps are costly and usually a time waster. Understanding your customers\u2019 needs and improving all areas of communication can help to mitigate this waste.<\/p>\n\n\n\n<p>These eight wastes will increase your costs, time, and resources. Lean manufacturing is designed to help any manufacturing organization improve efficiency and reduce costs. The goal of lean is to eliminate waste\u2014those components that do not add value to your operations. When it\u2019s done correctly, lean can produce substantial improvements in efficiency, productivity, cycle time, material costs, and defects, resulting in lower costs and improved competitiveness. Here is how it works.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">The five fundamental principles of lean manufacturing<\/h2>\n\n\n\n<p>Although lean has long been associated with improvements in manufacturing, the principles of lean can be applied\nto any business or industry. These principles\ncan even be used, on a smaller scale, to organize your office or workspace.&nbsp;<\/p>\n\n\n\n<p>These are the\nfive steps:<\/p>\n\n\n\n<p><strong>1. Value:<\/strong> Your\ncustomers will always define value for their product. You need to ask them the\nright questions to determine it, such as what is your timeline for\nmanufacturing and delivery? Are there other expectations or requirements? What\nis your price? Once you get these answers, you can provide value for that\ncustomer.<\/p>\n\n\n\n<p><strong>2.\nValue Stream:<\/strong> After you\nhave established the value, the next step\nis mapping the \u201cvalue stream.\u201d This part includes examining all the processes that\nare involved in taking the product from raw materials to delivering it to the\ncustomer as the final product. Value-stream mapping is not complicated, but it\nis crucial since it identifies every action throughout the process. <\/p>\n\n\n\n<p>On a one-page map, list the flow of materials\nwith the goal being to find wasteful steps that do not add value and then to\neliminate them. Going through this step should provide a complete understanding\nof the entire business operation. <\/p>\n\n\n\n<p><strong>3. Flow:<\/strong> Once the waste has been taken out of the value stream, the next step is to ensure that the remaining steps flow smoothly without interruptions, delays, or bottlenecks. This step could require breaking down the <a href=\"https:\/\/www.investopedia.com\/terms\/s\/silo-mentality.asp\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\">silo mentality<\/a> within the organization and making an effort to become cross-functional across all departments. While it won\u2019t be easy, doing so will probably result in substantial gains in productivity and efficiency.<\/p>\n\n\n\n<p><strong>4.\nPull:<\/strong> Improved\nflow means you can dramatically reduce the time it takes to get products to the\ncustomer. It now becomes easier for you\nto deliver your products, and your customers can start to \u201cpull\u201d the products\nfrom you as they need them. Because of the enhanced flow of your processes, you\nwon\u2019t need to manufacture products in advance or have costly inventory. Both\nyou and your customer end up saving money.<\/p>\n\n\n\n<p><strong>5.\nPerfection:<\/strong> While navigating\nthe first four steps is vital, step five is the most essential of all. In this\nfinal step, you\u2019ll be ensuring that lean\nthinking and process improvement become part of your company\u2019s culture. Even as\nyou witness the gains you\u2019re making, you must remember that lean manufacturing\nrequires a continuous effort to perfect. Every worker must be engaged in implementing\nlean. Experts in lean manufacturing\nstress that a process is not lean until it has been through value-stream\nmapping at least half a dozen times.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Every organization can improve by\nusing lean manufacturing techniques<\/h2>\n\n\n\n<p>Every company has a tremendous opportunity to grow by putting lean manufacturing into practice. The steps will enable your business to deliver the highest quality products at significantly lower costs. And that\u2019s something that should motivate anyone to give it a try!<\/p>\n\n\n\n<p><\/p>\n","protected":false},"excerpt":{"rendered":"<p>The premise of lean manufacturing is rather simple: companies must strive to eliminate waste from the manufacturing process.<\/p>\n","protected":false},"author":4,"featured_media":3447,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[94,93],"tags":[3],"class_list":["post-3443","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-tips","category-production-planning","tag-manufacturing"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v26.7 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>What is Lean Manufacturing? - Blog for Manufacturers and Distributors<\/title>\n<meta name=\"description\" content=\"Lean manufacturing in practice will enable your business to deliver the highest quality products at significantly lower costs. Read more form MRPeasy blog.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.mrpeasy.com\/blog\/what-is-lean-manufacturing\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"What is Lean Manufacturing? - Blog for Manufacturers and Distributors\" \/>\n<meta property=\"og:description\" content=\"Lean manufacturing in practice will enable your business to deliver the highest quality products at significantly lower costs. 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