It\u2019s a perennial problem for manufacturers. How do you reduce waste as far as possible? Waste can never be eliminated – it is part and parcel of producing anything. But it shouldn\u2019t unnecessarily impact the environment or prove detrimental to your team\u2019s productivity. Thankfully, there has been a concerted effort among manufacturers to implement what is known as \u2018lean production\u2019. It could help your business considerably.<\/p>\n\n\n\n
The main objective of lean production is to reduce waste as far as possible. It consists of a set of techniques and tools that are designed to streamline any manufacturer\u2019s processes.<\/p>\n\n\n\n
Lean production can be traced back to the Toyota Production System (TPS), which, contrary to our earlier suggestion, aims to eliminate<\/em> waste. Sometimes referred to as \u2018just-in-time\u2019 production, TPS relies on automation \u201cwith a human touch\u201d.<\/p>\n\n\n\n So, how could it benefit your operation?<\/p>\n\n\n\n If there\u2019s one thing that all great manufacturers share, it\u2019s their brilliant problem-solving ability. The great thing about lean production is that it forces you into that mindset. Rather than looking at the first problem or challenge within the production line, you\u2019re encouraged to dig far deeper. What is the root cause? How can it be fixed and then standardised for the future? More importantly, once you discover that root cause, the solution can be shared among the team to further their development, too.<\/p>\n\n\n\n This is where it gets pretty interesting. Did you know there are seven common areas in which waste can occur in manufacturing? It\u2019s more than you think, right? But these are the areas where you\u2019re likely losing time and effort without realising:<\/p>\n\n\n\n The best thing about the Seven Wastes is that it\u2019s pretty easy to identify where your problems might lie. For instance, how many product defects do you experience on a monthly basis? Has that number been rising? Similarly, is a drive to fulfil orders that fall through or never come off resulting in over-production?<\/p>\n\n\n\n Sometimes referred to as the \u20185S\u2019, or \u2018Five S\u2019, this is a Japanese term which refers to five lean manufacturing processes.<\/p>\n\n\n\n They are:<\/p>\n\n\n\n Put simply, if you implement the 5Ss, you\u2019ll end up with a workplace that functions far more efficiently simply because it\u2019s an easier place in which to work.<\/p>\n\n\n\n This is one of the simplest strategies for lean production but one that is so easily overlooked.<\/p>\n\n\n\n By reducing your batch quantities, you\u2019ll reduce the lead time before each customer receives their products. This is because they\u2019ll no longer have to wait for extra products to be manufactured. It also ensures that you\u2019ll set up the steps required to reduce that lead time and, in turn, operate on a far leaner basis.<\/p>\n\n\n\n Manufacturers always strive for quality within their processes, but it\u2019s not an easy thing to achieve at scale – or consistently.<\/p>\n\n\n\n However, a simple technique could save the day. By using red bins for defects and ensuring they only reside in those bins, you\u2019ll be able to identify defects more easily and work as a team to resolve them in the long term.<\/p>\n\n\n\nRigorous problem-solving<\/h2>\n\n\n\n
The Seven Wastes<\/h2>\n\n\n\n
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Visual management<\/h2>\n\n\n\n
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Reducing batch quantity<\/h2>\n\n\n\n
Red bins for quality<\/h2>\n\n\n\n