Lean Manufacturing
A quick definition of Lean Manufacturing, a derivative of the Toyota Production System (TPS), is that it is a set of principles and tools that helps to eliminate process activities that don't add value and to create "flow" in a process.
A Lean process is defined as one that uses only the absolute minimum of resources to add value to the service or product. In a Lean process, no people, equipment, or space are dedicated to rework. Lead times are minimal and everybody involved in the process performs only value-added tasks.
Processes in Lean methods are thought of as value streams. Lead time reduction and the flow of the value streams are the major areas of focus. Value-stream mapping helps teams understand the flow of material and information as the product is being processed through the organization, creating a vision of the entire system.
Lean methods, then, should be thought of as:
- A way to understand "value" from the viewpoint of the customer and eliminate activities that don't add value.
- A methodology to create a continuous flow of value-adding activities, pulled by the customer.
- A set of tools to continuously improve this flow.
They can be applied to manufacturing, service and transactional environments.
Combining Six Sigma and Lean methods can be very powerful if one uses a process management framework to identify opportunities for projects and if management understands how Six Sigma and Lean work together.
