Lean Production Ideas

Lean production has roots in Ford Motor Company, Toyota, the Japanese engineer Eiji Toyoda and his production engineer Taiichi Ohno and the depressed Japanese economy after World War II. Producing small quantities as needed creates cost savings and quality and is the basis of lean production.

Standardized Work

Standardized work is a tool for developing and improving production processes. It establishes clear procedures for how employees perform work, with the objective of eliminating error and improving quality. There are three principles that standardized work is based upon: Takt Time, Working Sequence and Standard In-Process Stock. Takt time is the rate that products need to be made at to meet customer demand. Working sequence is the order of operations in a process needed to produce a quality product in the time in which it's needed. Standard in-process stock is the minimum number of parts and materials that's needed always on hand to keep up a good production process. Standardized work is developed with worker input and is adjusted as improvements become apparent. It creates a stable process in which error and quality are controlled.

Just-in-Time

Just-in-time, or JIT, was introduced by Toyota in the 1950s to address problems facing the company, including the high cost of capital in a depressed and post-war economy, tough competition, fixed and falling prices and quickly changing technologies. JIT means producing the right quantity of the right item at the right time and is part of a total lean production system. The product doesn't get made and sit on a shelf awaiting sale. A basic principle of JIT is that the product isn't made until the customer wants it.

Jidoka

Jidoka is a Toyota concept of production that means designing defect-free processes through continuous improvement of process capability, containment of defects as they occur and feedback for improvement actions. Jidoka is a quality management concept that embraces the intelligent participation of the worker throughout production processes. Literal meaning of the word jidoka is the worker (ji), a motion or work (do) and the suffix "ation" (ka), automation with a human mind. Jidoka advocates input from the worker in the process and operator empowerment to balance and improve the process when errors or defects occur.

5S

5S is a Japanese concept of workplace conditions to contribute to lean production. 5S seeks to create and maintain a well-ordered workplace to save time and money and contribute to a smooth work process. There are five parts to 5S: Seiri or Sort, Seiton or Straighten and Set in Order, Seiso or Shine and Inspect, Seiketsu or Standardize and Shitsuke or Sustain.

Sort things in a work area to eliminate clutter and junk and only have what is needed and used. Straighten and set in order so things are organized in an easily accessible manner. Shine and inspect the work area at the end of each shift or each day so things are not left messy or out of place. Standardize work areas and work practices so everyone knows what is expected and how to perform in a consistent manner. Sustain the previous four practices so the system flows smoothly and is kept up.

References

• Lean Production Simplified; Dennis Pascal; 2002