Aside from competition, industrial manufacturers’ main struggle is keeping operations going against market instability and rising costs. In the search to reduce their production system expenses, certain manufacturers have begun adopting the principles of lean manufacturing. Let’s review the model and the 5 principles of lean manufacturing to help businesses improve production.

Want to Learn More About Breiner’s Partnership with Toyota?Click Here to Download!

What is Lean Manufacturing?

Lean manufacturing is a method of operation focused on minimizing production waste and maximizing productivity. Together, these principles review where energy can improve or is wasted throughout the entire organization: design, production, procurement, HR, administration, delivery, and customer services all fall under lean manufacturing’s umbrella.

These principles were first found in Toyota production systems. Once researchers observed the efficient production of Toyota’s cars and forklifts, they compiled these standards into what we now call lean manufacturing.

What are the 5 Principles of Lean Manufacturing?

1. Value

Value is defined by the customer’s needs from the product, such as expected pricing, manufacturing period, or time to delivery. Since these goals set the tone for the rest of the transaction, asking customers questions is vital to determining end-value and their commitment to the end purchase.

2. Value stream

Value streams use the customer’s values to identify all the actions involved throughout the production service from materials to final delivery. In lean manufacturing, this establishes each step in the business process needed to create value while removing unnecessary steps, helping manufacturers understand the entire system.

3. Flow

With waste removed from the lean manufacturing process, the next step is securing a smooth production flow; meaning no stops, disruptions, or blocks that waste time. The challenge is breaking down or reworking production steps for peak functionality across all departments. However, these developments will ultimately improve production speed, service, and quality for the business.

Man wearing safety gear on computer in factory

The guiding principle of lean manufacturing is the pursuit of continuous improvement.

4. Pull

Following improved flow, lean manufacturing implements the time to market, or pull, to customers. Pull makes sure inventory isn’t wasted by only manufacturing upon customer demand, continuing a timely production and delivery flow. Simultaneously, customers are able to “pull” the product from you anytime, freeing up inventory in weeks instead of months. By enabling pull for both manufacturers and customers, production materials are used continuously without needing to manage inventory.

5. Perfection

Perfection is by far the most important step, as it is where you incorporate the principles of lean manufacturing into your company processes and culture. While achieving perfection seems impossible, the constant pursuit to adapt and develop manufacturing production isn’t, though it does demand attentive action from the entire production staff to work. Whether you alter your production system a hundred or a thousand times, lean manufacturing should be a constant factor towards enhancing value for employees as well as customers.

Breiner an Lean Manufacturing

Manufacturers can credit Toyota for the principles of lean manufacturing used in their companies. Yet, for a quick and attentive response for quality emergency parts, Toyota Material Handling turns to Breiner Innovative. For an ensured, valuable customer experience getting your parts, contact us to see all that Breiner has to offer.

Common types of gasket materials. This helpful infographic takes a look at the most common types of gasket materials. Download your infographic here.