Lean manufacturing

Imagine if you could simplify your business so that nothing was wasted, like time, materials, and effort.  

Say hello to lean manufacturing – a way of doing business that reduces unnecessary stuff in production processes. Yes, it’s a methodology. But basically, it’s getting more done with fewer resources without sacrificing quality. 

Lean manufacturing means you’re always improving

Here’s the thing. It’s not just about streamlining processes. Lean manufacturing focuses you on how to constantly improve. Making small, manageable changes that can lead to big results over time.  

Maybe you’re thinking of competing with the rest of the world. Or maybe you are already successful overseas but are looking for ways to maintain your edge. Constantly improving your processes, building your people’s skills and growing some great leaders will get you there. 

Improve your productivity

The goal of lean manufacturing is to create a more flexible, responsive, and cost-effective business. It’s worked for businesses all around the world. 

Find what’s not working, get rid of it (or at least minimise it), and reap the benefits – better profitability and happy customers who get what they need. 

Lean manufacturing can also help you:

•  improve quality performance
•  increase productivity  
•  boost employee satisfaction and morale
•  reduce production and response time. 

The good thing is, lean manufacturing is adaptable. So you don’t need to invest heaps of time, money and resources.   

Follow these steps to improve a process using lean manufacturing. 

1. Identify the problem or opportunity you want to improve. 
2. Choose the best lean manufacturing technique based on the context. 
3. Form a team that has the range of skills needed.  
4. Collect and analyse data on what’s happening now. 
5. Develop and put in place the strategies to improve. 
6. Monitor the results and adjust anything if needed. 
7. Celebrate the success! 

Lean manufacturing is a mindset – a way of thinking. Grasp these five main principles and apply them as a whole to start practising Lean.

• Value stream mapping – visualise and map out your whole production process to find out what’s not working or inefficient. 
• 5S (Sort, Set in order, Shine, Standardize, Sustain) – organise your workplace to be super-efficient and safe by following the five steps.   
• Just-in-time production – produce only what’s needed, when it’s needed, so you don’t have expensive inventory and workers waiting around. 
• Continuous improvement (often called Kaizen) – encourage ongoing improvements that involve all employees, even up to top management. 
• Pull systems – produce products when the demand is there (the pull), so you don’t overstock or overproduce.  

Lean manufacturing tools and techniques

Lean manufacturing offers a range of tools and techniques. You might use different ones depending on your business. Here’s a handful of the most popular techniques. 

Six Sigma

Measure your processes, then use the data to see where you can reduce variations – that’s anything unexpected or uncontrolled. Motorola brought this popular technique to the world in the 1980’s.  

Six Sigma uses five stages to solve these problems in processes – Define, Measure, Analyse, Improve, Control (DMAIC). 

Total Quality Management (TQM)

Constantly look to improve processes and keep customers satisfied. You involve all employees and make sure they’re well trained.    

Theory of Constraints (TOC)

Manage the main thing that’s causing a problem or holding things back in a process to improve performance. 

Plan-Do-Check-Act (PDCA) cycle (sometimes known as Deming Cycle)

Follow this cycle of steps to continuously work out what’s working in your processes and what’s not.  

Automation can be helpful, but check if you need it

Lean manufacturing can mean adding advanced tech to your processes. If that’s the case, it’s super important to fully understand your processes and what tools you need for what tasks.  

Check if automation will move your business forward. Ask yourself: 

• Does that task need to be automated? 
• Will that fancy new tool give me value in the long term?
• Will that investment sustain the business for a long time? 

Technology changes quickly. To keep flexible, you want to invest in a tool that’s still going to do the job if things change, such as customer needs, your business model, or your processes. 

Get started with Lean

Well, all that info’s great, but where do I start? 

Advanced Manufacturing Aotearoa (AMA) is a great place to start. They’re on a mission to help manufacturers up their game.  

They want you to improve your productivity and output. And that means by adopting smart and modern technologies and process, so that you’re more productive, sustainable and globally competitive. 

And they have regional support groups throughout the country. Check in with AMA to see what’s available where you are. 

AMA — Advanced Manufacturing Aotearoa