lean
Lean Manufacturing, 5S and Six Sigma
Page 1 of 8
We’re big fans of lean manufacturing practices,
5S and Six Sigma based on the results we’ve seen in metal casting plants as well as in other manufacturing companies.
If you are not embracing and implementing these concepts, chances are your company is not moving forward. If you are not continually improving you are moving backwards relative to your competitors. LEAN MANUFACTURING
Lean manufacturing is the implementation of the concept that anything that does not create value in the product is to be eliminated. It is the concept of more value for less work. As trained industrial engineers, it seems pretty basic to us. Its simplicity is what makes it work. While the Japanese are rightfully given credit for re-vitalizing the concept of lean, its roots really go back to Frederick Winslow
Taylor of Bethlehem Steel in the 1880s and
1890s.
Then it was called “Scientific
Management.”
The Taylor approach starts with a clean slate – it designs the process to, as much as possible, only include steps that create value in the product. It is well suited for new plants, new products or new processes. The Japanese approach addresses existing plants, products and processes. It is focused on eliminating
“waste” (anything that is not adding value). As waste is reduced, quality improves, production times are reduced and cost is minimized.
Various methodologies are used as tools to achieve this including Value Stream Mapping,
5S, Kanban (pull systems) and error-proofing.
Our view is that starting with Taylor’s approach lets you establish the perfect world as a base line. Using the Japanese approach then helps you work toward the perfect world. Let’s use a casting example. A typical process might be to
cast, clean, finish, re-clean, machine and ship.
Why do we clean, finish and machine? We know these processes often can’t be eliminated but why not try? If the casting can be produced
Page 1 of 8
We’re big fans of lean manufacturing practices,
5S and Six Sigma based on the results we’ve seen in metal casting plants as well as in other manufacturing companies.
If you are not embracing and implementing these concepts, chances are your company is not moving forward. If you are not continually improving you are moving backwards relative to your competitors. LEAN MANUFACTURING
Lean manufacturing is the implementation of the concept that anything that does not create value in the product is to be eliminated. It is the concept of more value for less work. As trained industrial engineers, it seems pretty basic to us. Its simplicity is what makes it work. While the Japanese are rightfully given credit for re-vitalizing the concept of lean, its roots really go back to Frederick Winslow
Taylor of Bethlehem Steel in the 1880s and
1890s.
Then it was called “Scientific
Management.”
The Taylor approach starts with a clean slate – it designs the process to, as much as possible, only include steps that create value in the product. It is well suited for new plants, new products or new processes. The Japanese approach addresses existing plants, products and processes. It is focused on eliminating
“waste” (anything that is not adding value). As waste is reduced, quality improves, production times are reduced and cost is minimized.
Various methodologies are used as tools to achieve this including Value Stream Mapping,
5S, Kanban (pull systems) and error-proofing.
Our view is that starting with Taylor’s approach lets you establish the perfect world as a base line. Using the Japanese approach then helps you work toward the perfect world. Let’s use a casting example. A typical process might be to
cast, clean, finish, re-clean, machine and ship.
Why do we clean, finish and machine? We know these processes often can’t be eliminated but why not try? If the casting can be produced