What’s LEAN

INTRODUCTION TO SOME ASPECTS OF LEAN

“What is Lean? This is a question that many people wonder about, and nowadays, companies require their employees to have a foundational knowledge of Lean and its tools. Lean is considered a philosophy of streamlined management that companies aspire to.

So, what is Lean? Let’s explore through.

Lean is a set of tools used to improve and enhance productivity without sacrificing or compromising other aspects.

Lean provides unique value to your customers with the assistance of minimal organizational resources.”

THE THREE FORMS OF WASTE IN LEAN

1. Muda (Non-Value-Adding Waste): This refers to any activity or process that consumes resources but does not add value to the customer. Examples include unnecessary transportation, overproduction, excess inventory, and waiting times.
2. Muri (Overburden Waste): This type of waste occurs when there is an excessive burden or strain placed on resources, equipment, or personnel. It can result in inefficiencies, errors, and unnecessary stress.
3. Mura (Inconsistency Waste): Mura refers to variations and inconsistencies in processes, production, or demand. It leads to inefficiencies, uneven workloads, and the need for constant adjustments or rework.

By identifying and eliminating these forms of waste, Lean aims to optimize processes, enhance value delivery, and improve overall efficiency.

7 TYPES OF MUDA WASTE IN LEAN: TIMWOOD

In Lean, there are seven types of waste, often referred to as TIMWOOD, which stands for

1. Transportation: Unnecessary movement or transportation of materials or products adds no value and can result in delays, damage, or excess handling.
2. Inventory: Excess inventory beyond what is necessary for immediate use ties up capital and space, increases the risk of obsolescence, and can lead to waste through spoilage or damage.
3. Motion: Unnecessary motion or movement of people or equipment that does not contribute to the value-added process is wasteful and can lead to inefficiencies and fatigue.
4. Waiting: Idle time or waiting for materials, information, or approvals disrupts the workflow and delays the completion of tasks, resulting in wasted time and reduced productivity.
5. Overproduction: Producing more than what is immediately required by the customer leads to excess inventory, increased lead times, and potential waste if demand does not match the production output.
6. Overprocessing: Performing unnecessary or non-value-adding steps in the process that do not contribute to meeting customer requirements or quality standards.
7. Defects: Quality issues, defects, or errors that require rework, scrap, or customer complaints result in wasted resources, time, and materials.

THE HOUSE OF LEAN

“The House of Lean” is a metaphorical representation that illustrates the key concepts and principles of Lean methodology. It consists of two main pillars:

1. Respect for People: The foundation of the house represents respect for people, emphasizing the importance of creating a positive work environment, fostering teamwork, empowering employees, and valuing their contributions.
2. Continuous Improvement: The roof of the house symbolizes continuous improvement, also known as Kaizen. It involves constantly seeking ways to enhance processes, eliminate waste, and improve efficiency and quality.

The House of Lean also includes several supporting elements:

• Just-in-Time (JIT): This element focuses on delivering the right product or service at the right time and in the right quantity to minimize waste, reduce inventory, and respond quickly to customer demands.
• Jidoka (Autonomation): Jidoka emphasizes building quality into the process and stopping production when abnormalities or defects are detected, ensuring that problems are addressed at their source.
• Standardization: Standardization involves establishing clear and standardized work processes, procedures, and guidelines to create consistency, reduce variability, and enable continuous improvement.
• Visual Management: Visual management utilizes visual cues, such as charts, signs, and displays, to communicate information, provide transparency, and enable better decision-making.
• Value Stream Mapping: Value stream mapping helps identify and analyze the flow of materials, information, and activities across the entire value chain, enabling organizations to identify areas of waste and optimize processes.

By building this “house” and embracing its principles, organizations can create a culture of continuous improvement, waste reduction, and customer focus, leading to improved efficiency, quality, and overall performance.