Lean Manufacturing

Lean Manufacturing is probably the single most important opportunity for American manufacturers to implement changes that quickly and directly improve their competitive position through productivity improvements and reduced waste. It's based on the fundamental principle that anything that does not add value to the product is waste and must be eliminated.

What is Lean Manufacturing?

In essence, Lean, also known as 'Flow' manufacturing, is a systematic approach to identifying and eliminating waste (non-value added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection. It includes processes and methodologies that have evolved into world-class best practices for manufacturers. It typifies the best in leadership, culture, strategy and customer focus that define highly successful manufacturers today.

Lean is about growth. If, as a business owner, you view Lean manufacturing as a way to reducing your work force, you're missing the point. If you want your company to grow, you need to free up people, space and equipment to do more, invest in new product developments, new markets and new ways of working. If you don't believe it, value stream map your process, and hold just one Kaizen event and see what happens. See what these business owners had to say about how Lean affected their growth plans.

Rod Bayard - Bestweld, Inc.

History of Lean

In essence, Lean, also known as 'Flow' manufacturing, is a systematic approach to identifying and eliminating waste (non-value added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection. It includes processes and methodologies that have evolved into world-class best practices for manufacturers. It typifies the best in leadership, culture, strategy and customer focus that define highly successful manufacturers today.

Lean is about growth. If, as a business owner, you view Lean manufacturing as a way to reducing your work force, you're missing the point. If you want your company to grow, you need to free up people, space and equipment to do more, invest in new product developments, new markets and new ways of working. If you don't believe it, value stream map your process, and hold just one Kaizen event and see what happens. See what these business owners had to say about how Lean affected their growth plans.

A Brief History of Lean (PDF Format).

Current Practices of Lean Manufacturing

Manufacturers are facing increased worldwide competition and the stakes are high. When presented with proven successes of up to 50 - 60 - even 75% overall improvements in total lead-time have been reported, it's hard to understand why so many American manufacturers are still unfamiliar with Lean.

The benefits are clear:

Making the Transition to Lean

The first step toward Lean Manufacturing is the simplest, but the most difficult...you must be ready to change. And according to Masaaki Imai, you have to have three things:

• Top level commitment
• Top level commitment
• Top level commitment

It's never been as clear as it is today that for many businesses to survive international competition, they have to make changes. If you're ready and dedicated to making change work, you're ready to begin your transformation into becoming a Lean Enterprise.

Getting Started

Getting started toward Lean is as simple as calling the DVIRC representative in your county. All you have to provide is the commitment - we'll provide the tools. With an assessment and by value stream mapping your organization, we can provide you with a complete program to get your organization on the path to being a Lean Enterprise.

The Lean Enterprise and Lean Transformation

Lean Transformation and Lean Enterprise are buzz terms you will hear a lot about. "Lean Transformation" is basically setting the course, making the commitment, getting the training and tools you need to move through the process of becoming Lean. "Lean Enterprise" is a term often used to describe a business that produces more with existing resources by eliminating non-value added activities. This is a company that has embraced Lean methods and eliminated waste. But, there's no real set time frame for a Lean Transformation program, or becoming a Lean Enterprise, because by definition, Lean is a continuous improvement process. Once you've embraced the culture, you are continually working to transform the way you do business in becoming more and more customer focused, and more efficient.

While each Lean program that the DVIRC develops is customized to the company's needs, click here to see a typical launch. If you're ready to begin your Lean Transformation, just contact the DVIRC representative in your county.

DVIRC Lean Transformation (PDF Format).

Lean Practices

Lean identifies eight types of waste:

Inventory (more than one piece flow)

Overproduction (more or sooner than needed)

Correction (inspection and rework)

Material movement

Waiting

Motion

Non-value added processing (NVA)

Information

Typically 95% of total lead-time is non-value added!

Here's an overview of our Lean services. We recommend you start by involving your employees right up front. Identify a team, and have them, along with senior management, complete the DVIRC's Lean Certification Level One, through our Institute for World Class Manufacturing®. The foundation of this information is critical. You'll learn about most of these practices, and visit plants where they are being implemented. Click on each of the topics below for more information about Lean practices. Contact your DVIRC representative for more information.

DVIRC Customers Talk About Lean Manufacturing

Lean Case Studies

More Information About Lean Manufacturing

If you'd like more information about Lean Manufacturing, visit these websites: