LEAN MANUFACTURING

What is LEAN?

Lean manufacturing is a methodology for maximizing customer value while minimizing waste in production. In practice, it means streamlining processes to only use the necessary resources and eliminate activities that don’t add value.

USES and ORIGINS OF LEAN Manufacturing

Lean’s origins trace back to the Toyota Production System (TPS) developed in Japan after WWII. Faced with resource shortages in the 1950s, Toyota engineers Taiichi Ohno and Eiji Toyoda pioneered a discipline of eliminating waste and continuously improving processes to do more with less. TPS introduced practices like just-in-time production and jidoka (built-in quality) which formed the foundation of Lean manufacturing.

Productivity + Quality + Costs = Profitability

PHILOSOPHY

One of Lean Manufacturing’s foundations is Kaizen, which means continuous improvement. Kaizen is a management philosophy that involves the entire organization in improving processes, products, and services. It focuses on waste elimination and increasing value for the customer.

Toyota 1950- Henry Ford started first

1990s- the rest of the world followed

Eight Types of Wastes

  • inventory
  • transportation
  • overproduction
  • overprocessing
  • underutilised people
  • scraps
  • efforts
  • movement

LEAN Principles

These five principles – Value, Value Stream, Flow, Pull, and Continuous Improvement – provide a high-level guide to implementing Lean. Next, we’ll dig into some specific tools and concepts (the “Lean toolbox”) that support these principles day-to-day.

  • value
  • value stream
  • flow
  • pull
  • perfection

Benefits of LEAN

  • Increased efficiency: Streamlining processes to eliminate waste and improve productivity. 
  • Reduced costs: Lowering operational costs by minimizing waste and optimizing resources.
  • Improved product quality: Enhancing the quality of products through continuous improvement practices. 
  • Higher customer satisfaction: Delivering better value to customers by focusing on their needs and reducing lead times. 
  • Enhanced team engagement: Fostering a culture of continuous improvement and collaboration among team members.These benefits contribute to a more agile and responsive organization.

Morale and Motivation improves

PDCA Improvement Cycle (Deming)

It’s often helpful to follow a structured model like PDCA (Plan-Do-Check-Act) for each change: plan the improvement, do it (on a small scale), check results, and act to standardize if successful. At this stage, you may be running multiple Lean projects in parallel (under the coordination of your Lean team).

Flow Process Analysis

The American Society of Mechanical Engineers Symbols- deploying flow process analysis

Lean Manufacturing: Principles, Tools, Case Studies (2025 Guide)

Understanding Lean Manufacturing | KAIZEN Article

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About Daniella-Jade Lowe

Hello, My name is Daniella Jade Lowe. I am a PURSUN researcher and I am working on marketing myself as an Accessibility Consultant. Journalism and Politics are my passion. I have a BA degree in History and Politics. What type of disability do you have? At birth, I was diagnosed with Spina Bifida and Hydrocephalus which are neurological conditions. As a result, I use a wheelchair for mobility. What is disability to you? The only disability is a bad attitude. I have a disability. It doesn’t completely define me; it just enhances me in a way which differentiates and strengthens me. My disability should be viewed as an ability: to see the world in a different way. I don’t really like the term because sometimes it indirectly implies someone is dysfunctional or helpless. The most important thing is to never make assumptions. Someone with a disability can be very, physically, fit and strong, highly intelligent and articulate. What has been your experience from the time you remember till now? - positive and negative experiences. My life as a wheelchair user has been generally okay. Wheelchair Accessibility is frustrating. I was teased a little in school. Other than that, life is great. How do you cope with: -daily activities - your disability, do you have times when you are down - people's reactions towards you. I have carers, a Social worker, District Nurses, a GP, and extended family in this country. I am also in contact with a local disability charity in Yorkshire. I also have a friendly landlord. How do you keep yourself motivated? I must stay organised and practice good time management. I also prioritise my plans. What is your word or advice - to those with disabilities? - to the society Don’t let people put you in a box. You have a voice, use it. 10. Tell us about your platforms if you have any- Blog: The View from Where I Sit Facebook: Daniella Jade Lowe Instagram: @daniellajadelowe/@theviewfromwheresitblog Thank you!