Lean Manufacturing
Lean Manufacturing
05 Jul

Lean manufacturing or lean thinking is the core idea of relentlessly working on eliminating waste from the manufacturing process. This management philosophy is derived mostly from the Toyota Production System (TPS)  Developed by the Toyota executive Taiichi Ohno. 

Effectively Lean Manufacturing is the systematic reduction of waste!


The Seven Wastes

  • Overproduction
  • Transportation
  • Inventory or Storage
  • Inappropriate Processing
  • Waiting
  • Motion
  • Defects or Correction

TotalControlPro™  can support you in reducing these wastes through live visibility of your production floor, employee productivity & audit trail of their work updated on your digital whiteboard instantly, with clear and simple business intelligence reporting to allow you to identify areas of weakness in your process. All with the added capability of reducing paperwork from the factory floor and increasing productivity possibly saving you 130 production hours per employee per year!

There are several key lean manufacturing principles to implement lean manufacturing to your manufacturing flow.

  • Improve quality: To stay competitive in today's marketplace, a company must understand its customers' wants and needs and design processes to meet their expectations and requirements.
  • Eliminate waste: Waste is any activity that consumes time, resources, or space but does not add any value to the product or service.
  • Reduce time: Reducing the time it takes to finish an activity from start to finish is one of the most effective ways to eliminate waste and lower costs.
  • Reduce total costs: To minimize cost, a company must produce only to customer demand. Overproduction increases a company’s inventory costs because of storage needs.

Design a simple manufacturing system

A fundamental principle of lean manufacturing is demand-based flow manufacturing. In this type of production setting, inventory is only pulled through each production center when it is needed to meet a customer's order. The benefits of this goal include:[30]

  • Decreased cycle time
  • Less inventory
  • Increased productivity
  • Increased capital equipment utilization

Continuous improvement

A continuous improvement mindset is essential to reach the company's goals. The term "continuous improvement" means incremental improvement of products, processes, or services over time, with the goal of reducing waste to improve workplace functionality, customer service, or product performance. Lean is founded on the concept of continuous and incremental improvements on product and process while eliminating redundant activities. "The value of adding activities are simply only those things the customer is willing to pay for, everything else is waste, and should be eliminated, simplified, reduced, or integrated" (Rizzardo, 2003). Improving the flow of material through new ideal system layouts at the customer's required rate would reduce waste in material movement and inventory


Overall equipment effectiveness (OEE) is a set of performance metrics that fit well in a lean environment. Also, PMTS, methods-time measurement, cost analysis and perhaps time study can be used to evaluate the wastes and IT effectiveness in the operational processes. For example, Jun-Ing Ker and Yichuan Wang analyze two prescribing technologies, namely no carbon required (NCR) and digital scanning technologies to quantify the advantages of the medication ordering, transcribing, and dispensing process in a multi-hospital health system. With comparison between these two technologies,the statistical analysis results show a significant reduction on process times by adopting digital scanning technology. The results indicated a reduction of 54.5% in queue time, 32.4% in order entry time, 76.9% in outgoing delay time, and 67.7% in outgoing transit time with the use of digital scanning technology

Request a Demo to see how with TotalControlPro™ you can gain a clear understanding of your WIP (work in progress) as well as finished product that needs to be processed! Increase your productivity & accountability, while reducing QC errors and waste with live audit trails and time tracking of all employees, jobs and parts! 

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