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This study of the efficiency of various plants around the world showed that the most efficient companies eliminated waste and focused attention on value adding processes.
The objective of the Lean approach is to provide techniques that enable companies to define value in their products, identify where and how this value is added and arrange these activities so that minimum waste is incurred. Lean also focuses on how to produce products only when they are needed, often known as “Just in time”. The ultimate aim of Lean manufacturing is to eliminate waste completely from the product creation process.
Lean manufacturing focuses on the reduction of the seven wastes to improve overall customer value:
Transportation – moving products further than is minimally required
Inventory – having more inventory than is minimally required
Motion – people moving or walking more than miminally required
Waiting time – products waiting on the next production stage, or people waiting for work to do
Over-production – making more than what is needed, or making it earlier than needed
Processing itself – relates to standalone processes that are not linked to upstream or downstream processess
Defective products – the effort involved in inspection for and fixing defects
So by eliminating waste, quality is improved, production time and costs are reduced.
How can we apply this to the workplace?
One method is the by using the 5S method.
5S Workplace organisation
- Sort – Sort out required from non-required items
- Straighten – Everything should be arranged orderly and be easy to find
- Sweep – Eliminate trash and dirt in the factory or office.
- Systemise – Establishing work practices to make the above happen
- Sustain – Practice and repeat all of the above until it becomes a way of life.