Principles and Practices of Lean Manufacturing
Introduction
What is Lean Manufacturing?

A major advance in manufacturing strategy
 Craft to Mass - 9:1 improvement in efficIEncy
Mass to Lean - 2+:1 improvement in efficIEncy
Pioneered and Developed by Toyota Manufacturing
Contrast: Traditional vs. Lean
Traditional Manufacturing
Lean Manufacturng
Contrast: Traditional vs. Lean
Traditional
Functional layout
Batch-and-queue
Product routing
Reduce setup frequency

Lean
Process layout
One-pIEce-flow
Sequential routing
Reduce setup duration
Contrast: Traditional vs. Lean (cont.)
Traditional
Specialized workers
Managed workers
Arms and legs
Attain staBIlity through buffering
Lean
Flexible workers
Empowered workers
Intellectuals
Attain staBIlity through synchronized, reliable processes

Contrast: Traditional vs. Lean (cont.)
Traditional
Statistical quality control
Schedule production, push
Make-to-forecast
EOQ, Inventory models
Lean
Quality at the source
Authorize production, pull
Make-to-order
Frequent, small-lot, sequenced delivery