Using lean manufacturing to reduce costs and improve quality
The Toyota seven wastes are as follows:
Lean Manufacturing is based entirely on solving the problem of waste. It details a constant process of analysis, production and mistake-proofing. Lean Manufacturing is a holistic, comprehensive, enterprise-wide program designed to be integrated into your company's core strategy. Many experts believe Lean Manufacturing strategy is the most effective way to launch and sustain lean activities.
Why would I use Lean Manufacturing?
Implementation of Lean Manufacturing
A good way to start is to set up a checklist and review it often. Product design can be cut in half with a few brainstorming sessions that improve overall company cost and performance.
Having an effective and efficient leader is a must! Toyota used a system of coaching and guiding the less experienced companies in their division. Implementing Lean Manufacturing is an entire cultural change, not just a focus on tools and methodologies.
In 2005/06, Warwick University found that Lean methods were applicable to the public sector, but most results were achieved by using a more restricted range of techniques with Lean Manufacturing. This study showed to most companies that they needed to encourage harder involvement and clear communication in the process.
Many companies have had outstanding results from implementing Lean Manufacturing. Cefla Group published they have accelerated business process by 87%. General Motors has implied Lean Manufacturing to cut down administration costs. They reported a $200 million dollar savings for halting the printing of catalogs for dealers. Chrysler also reported savings upward of $2 million by implementing Lean Manufacturing. Many other companies have reported cutting costs by 10% to 40% and increased productivity by 12% to 52%.
If Lean Manufacturing in applied with the correct idea's and tool's in mind, your company will be moving manufacturing forward in leaps and bounds!