Top 10 FAQs about Lean Manufacturing

  • A methodology to maximize customer value while minimizing waste, focusing on efficiency, process strengthening, and continuous improvement.

  • Typically, these are: Identify Value, Map the Value Stream, Create Flow, Establish Pull, and Seek Perfection (Continuous Improvement).

  • Often remembered by the acronym DOWNTIME: Defects, Overproduction, Waiting, Non-utilized Talent, Transportation, Inventory, Motion, Excess Processing

  • Begin by mapping your current value stream to identify waste, focus on bottlenecks (constraints), standardize work, and get employee buy-in.

  • A visual tool to map material and information flows from customer order to delivery, revealing waste and opportunities for improvement.

  • No, Lean principles apply to any process or industry (healthcare, software, services) to improve efficiency and reduce waste.

  • 5S (Sort, Set in Order, Shine, Standardize, Sustain), Kanban (pull signals), Total Productive Maintenance (TPM), Kaizen (continuous improvement events).

  • Track key metrics like lead time, productivity (units/hour), quality (defects), inventory turns, and Overall Equipment Effectiveness (OEE).