{"id":5,"date":"2022-07-14T14:54:38","date_gmt":"2022-07-14T14:54:38","guid":{"rendered":"https:\/\/pressbooks.palni.org\/spcleanmanufacturing\/?p=5"},"modified":"2022-08-15T19:05:54","modified_gmt":"2022-08-15T19:05:54","slug":"chapter-1","status":"publish","type":"chapter","link":"https:\/\/pressbooks.palni.org\/spcleanmanufacturing\/chapter\/chapter-1\/","title":{"raw":"Chapter 1: Introduction to Lean Manufacturing","rendered":"Chapter 1: Introduction to Lean Manufacturing"},"content":{"raw":"

Chapter 1: Introduction to Lean Manufacturing<\/h2>\r\n\r\n
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Overview<\/h2>\r\nLean manufacturing is the production method used to reduce production times as well as response times to customers.\u00a0 Lean manufacturing adopts a method of manufacturing according to demand, but also attempts to reduce waste. Generally, this process will include marketing and customer service personnel who can identify the wants of its customer base and report back to the manufacturer (Kulkarni et al., 2021; Gil-Vilda et al., 2021). The transition from a traditional company to a lean company is complex and needs to be carefully organized in order to maximize income, reduce costs, and to improve productivity (Cimermancic et al., 2022; Pearce & Pons, 2013). Review the slides and video below to learn more about the history of manufacturing and the shift to lean manufacturing. Use the double pointed arrow in the lower right corner to expand slides to full screen.\r\n\r\n \r\n\r\n[h5p id=\"1\"]\r\n\r\n \r\n

Lean Operations<\/h2>\r\n[h5p id=\"8\"]\r\n\r\nLean refers to an item being as slim as possible, like there is no fat, no waste. The fat or waste in a company would be excessive or inefficient operations, but lean manufacturing has no waste (Boardman; Kulkari et al., 2021). There are eight kinds of waste (or [pb_glossary id=\"85\"]muda[\/pb_glossary]) in some models. They are: transport, inventory, motion, waiting, over-production, over-processing, defects, and skills. Lean manufacturing focuses on the five following concepts as a way to reduce all of these kinds of waste (Boardman; Brown, 2020; de Bucourt et al., 2011).\r\n

Value and Value Stream<\/h3>\r\n[caption id=\"attachment_92\" align=\"alignleft\" width=\"451\"]\"Value<\/a> Value Stream Mapping of Rope Manufacturing (Yuvamitra, et al. 2017). Select the image to enlarge.[\/caption]\r\n\r\nThis concept is defined by the customer. The organization must have a clear understanding of what value is for the customer. It is wasteful to create a product that customers do not find value in buying (ASCM, 2022). Data provided by continuous customer feedback is how this concept is defined and constantly adapted to meet the needs of the customer base (Boardman). Consider the surveys provided at the end of receipts to elicit feedback on your shopping experience. This type of feedback is important for an organization to adapt with trends and demands.\r\n\r\nTo track the value of a product, a value stream map can identify the activities that add value or not, including the processes that are essential and cannot be eliminated. Terms to know are [pb_glossary id=\"87\"]value added[\/pb_glossary], [pb_glossary id=\"88\"]non-value added[\/pb_glossary], and [pb_glossary id=\"89\"]essential non-value added[\/pb_glossary] (Boardman). Learn more about value stream mapping from these resources:\r\n