¿Qué es el Lean Manufacturing?

Enviado por Andreina Medina • 29 de Junio de 2019 • Reseña • 1.722 Palabras (7 Páginas) • 118 Visitas

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Lean Manufacturing – Ingles

What is Lean Manufacturing?

Lean manufacturing is a systematic method originating in the Japanese manufacturing industry for the minimization of waste within a manufacturing system without sacrificing productivity, which can cause problems. Lean also takes into account waste created through overburden and unevenness in workloads. Working from the perspective of the client who consumes a product or service, "value" is any action or process that a customer would be willing to pay for.

Lean manufacturing attempts to make obvious what adds value, through reducing everything else (because it is not adding value). This management philosophy is derived mostly from the Toyota Production System (TPS) and identified as "lean" only in the 1990s. TPS is renowned for its focus on reduction of the original Toyota seven wastes to improve overall customer value, but there are varying perspectives on how this is best achieved. The steady growth of Toyota, from a small company to the world's largest automaker, has focused attention on how it has achieved this success.

Origin

This manufacturing efficiency improvement methodology was conceived in Japan by Taiichi Ohno, director and consultant at Toyota. Entered in 1937, Ohno observed that before the war, Japanese productivity was much lower than that of the United States. After the war, Ohno visited the United States, where he studied the country's leading productivity and waste reduction pioneers such as Frederick Taylor and Henry Ford.

Ohno found in them a perfect example of his idea of managing reduced inventories, eliminating unnecessary steps and controlling primary activities and giving control to the one who does the work (in this case the client) as support for the value chain. The Japanese word mute means 'waste' and refers specifically to any human activity that consumes resources and does not create value. The term Lean Manufacturing begins when the golden days of mass automobile manufacturing in the U.S. end in 1976 as a result of Chrysler's bankruptcy and GM and Ford's money losses; the second oil crisis that led U.S. automobile production to a 22% drop in production; and interest in Japanese manufacturing techniques and, in particular, Toyota's production system.

What is the purpose of lean manufacturing?

The purpose is to find tools that help eliminate all waste and all operations that do not add value to the product or processes, increasing the value of each activity performed and eliminating what is not required. This manufacturing process is related to the use of activity-based costing, which -according to its original version- seeks to relate costs to all the values that the customer perceives in the product. On the other hand, it serves to implement a philosophy of continuous improvement that allows companies to reduce their costs, improve processes and eliminate waste to increase customer satisfaction and maintain the profit margin. The purpose of lean manufacturing is to be useful to the community which implies being in search of continuous improvement.

Key principles of Lean Manufacturing

Perfect quality the first time: search for zero defects, detection and solution of problems at their source.

Minimization of waste: elimination of all non-value-added activities and safety nets, optimization of the use of scarce resources (capital, people and space).

Continuous improvement: cost reduction, quality improvement, increased productivity and information sharing.

Pull processes: products are pulled (in the sense of requested) by the final customer, not pushed by the end of production.

Flexibility: quickly produce different mixtures of a wide variety of products, without sacrificing efficiency due to lower production volumes.

Building and maintaining: a long-term relationship with suppliers by making agreements to share risk, costs and information.

Types of waste

Movement: The waste of movement has two elements, the human movement and the movement of machines, these movements are related to the ergonomics of the place where you work, thus affecting quality and safety.

Overproduction: It is the one that most affects an industry, it arises when continuous operations had to be stopped or when forecast products are made, for stock, before the customer orders them.

Wait: Term applied in those periods of inactivity of a process since this action does not add value and sometimes results in an additional cost of the product.

Transport: It refers to the unnecessary movement of materials from one operation to another without being required.

Extra Processing: Refers to extra operations such as rework, reprocessing, handling of unnecessary materials and storage due to a defect, overproduction or insufficient inventory.

Correction: relates to the need to correct defective products. It consists of all materials, time and energy involved in repairing defects.

Inventory: conditions when flow is restricted in a plant and when production is not moving at a rate. Production of inventory that no one wants at that time wastes space and stimulates product damage and obsolescence.

Disconnected knowledge: exists when there is a disconnection between the company with its customers and/or suppliers.