The Most Effective Lean Techniques in Manufacturing

In recent years, the topic of lean manufacturing has become increasingly popular, especially as improving efficiency and sustainability are becoming the focus of many manufacturers and businesses.

Lean manufacturing allows businesses to streamline their workflows, eliminate bottlenecks, and automate some processes, so they can manufacture products more quickly and with higher quality.

There are various methodologies and approaches to lean manufacturing available at the moment. Yet, while more options are, in most cases, a good thing, choosing the most effective ones for your business can be challenging in practice.

In this guide, we will explore some of the most popular and effective lean manufacturing techniques and provide in-depth coverage of each one. 

By the end of this article, you’ll have learned about the following:

1. The benefits of different lean manufacturing techniques
2. Steps involved in implementing each technique
3. Real-world examples of each technique

You will have a better understanding of the most effective lean manufacturing techniques available, and especially how to implement them in your own manufacturing process.

What is lean manufacturing?

Lean manufacturing, simply put, is a methodology that aims to make a manufacturing process “leaner” by reducing or eliminating non-value-added activities in the manufacturing process. The aim is that eliminating these redundant activities will minimize waste, reduce cost, and improve the manufacturing process’s efficiency.

Lean manufacturing is not a one-off activity but rather a continuous optimization process striving to reduce manufacturing cycle time, improve production quality, and ultimately increase customer satisfaction.

How can lean manufacturing benefit manufacturers?

The core process in lean manufacturing is identifying and eliminating non-value-added activities in the manufacturing process, such as unnecessary waiting time, excess inventory, or overproduction, among others. This will result in several key benefits:

1.  Increased efficiency: by eliminating these unnecessary activities, manufacturers can eliminate sources of waste in the manufacturing process, produce products more efficiently, and use fewer resources throughout the manufacturing cycles.
2. Improved product quality: lean manufacturing helps manufacturers identify sources of defects and errors in the manufacturing process and how to eliminate them. This, in turn, can help increase the manufactured products’ quality, reduce the risk of recalls, improve customer satisfaction, and grow as a business. 
3.  Improved cost-efficiency: lean manufacturing can also help reduce costs. By improving efficiency, manufacturers can reduce material, labor, and overhead costs, resulting in significant cost savings and improved profitability. 
4. Increased customer satisfaction: lean manufacturing is naturally customer-focused, with the ultimate objective being to provide optimal-quality products that meet or exceed customers’ expectations. By improving product quality and reducing cycle times, lean manufacturing can help improve customer satisfaction and loyalty.
5. Improved competitive advantage: lean manufacturing allows manufacturers to manufacture high-quality products at a lower cost than their competitors. Ultimately, this will provide the said manufacturer with a competitive advantage so they can gain a bigger market share, increased revenue, and improved profitability.
   
   

In short, implementing lean manufacturing can help manufacturers and businesses improve efficiency, reduce manufacturing/operational costs, and especially stay competitive in today’s highly competitive market. 

With these clear benefits of lean manufacturing, ultimately, manufacturers that have implemented lean manufacturing can achieve significant improvements in customer satisfaction, revenue, and profitability. 

4 Most Effective Lean Manufacturing techniques

Below, we will explore four of the most effective lean techniques in manufacturing and cover an in-depth analysis of each one. 

Let’s begin with the first one:

1. Total Productive Maintenance (TPM)

In manufacturing, Total Productive Maintenance (TPM) is often considered the most important lean technique, focused on maximizing the effectiveness and efficiency of equipment through productive maintenance.

It originated in Japan back in the 1950s, and one of the emphases of the lean technique is to involve everyone in the maintenance process—not just the maintenance personnel. 

TPM is also popular due to its close relation to OEE software, one of the most important performance metrics in manufacturing. In fact, the main objective of TPM is to improve the OEE of equipment by reducing downtime as much as possible and improving product quality. 

Benefits of Total Productive Maintenance

TPM is focused on improving the effectiveness of equipment, which in turn, can provide the manufacturers with the following benefits:

1. Reduced maintenance costs: Proactive maintenance of equipment can help reduce long-term maintenance costs due to the decreasing issues and breakdowns, both in terms of quantity (frequency) and quality (severity.) 

1. Extending equipment’s lifetime: TPM, as discussed, can reduce the frequency and severity of breakdowns, naturally extending the equipment’s life. Ultimately, this will result in reduced costs you’d otherwise need to replace this equipment.

1. Improved reliability and uptime: Proactive maintenance and continuous optimization as the results of TPM can help manufacturers reduce equipment downtime, which will also result in increased production capacity, more chances for on-time delivery, and improved customer satisfaction.

1. Increased employee ownership of equipment: A core aspect of TPM is involving all employees in the maintenance process. This can result in increased ownership of equipment, improved engagement, and a continuous increase in employee satisfaction. 

1. Improved product quality: By optimizing the performance of equipment, TPM can effectively reduce equipment downtime, errors, and defects, improving the manufactured product’s quality in the process.
   
   

How to implement Total Productive Maintenance

A key characteristic of TPM is how it involves everyone in the organization in a structured maintenance process, and here are the steps involved in achieving that objective:

1. Planning: create a comprehensive plan on how you are going to implement the TPM. Identify which pieces of equipment and assets are going to be included in the TPM program, and establish a dedicated team that will be responsible for implementing TPM. Ideally, the team should be cross-functional and at least include representatives from management/executive, maintenance, production, and quality control.

1. Assessment and inspection: conduct a thorough assessment and inspection of equipment to identify any potential issues. At this step, you may also perform basic cleaning of the equipment, so you won’t miss any potential sources of defects. The objective of this step is to establish a baseline for the equipment’s current performance.

1. Establish SOP for regular maintenance: train maintenance personnel and operators on how to perform regular maintenance tasks (inspection, lubrication, cleaning, etc.) Develop clear policies on how this routine maintenance should be performed and train your team accordingly.

1. Schedule preventive maintenance: establish a clear schedule for preventive maintenance tasks (part replacements, deep cleaning, equipment overhaul, etc.) Develop these schedules while taking the production requirements and current equipment performance into account. 

1. Optimization: identify bottlenecks, inefficiencies, and sources of defects, and implement the required corrective actions to improve manufacturing efficiency and product quality.

1. Training: provide onboarding training for new employees and regular training for all employees. The goal is to enable them with the required skills and knowledge necessary to participate in maintenance activities. Consider training employees on equipment maintenance, problem-solving skills, and continuous improvement. 

1. Monitor and improve: continuous improvement is highly critical to the TPM’s success. Track performance metrics and KPIs to monitor the effectiveness of TPM implementation and make the necessary adjustments. Invest in the right tools and technologies, such as smart factory solutions by LineView, to monitor performance accurately and identify areas of improvement. 

2. 5S Methodology

The name “5s” stands for Seiri (Sort), Seiton (Set in Order), Seiso (Shine), Seiketsu (Standardize), and Shitsuke (Sustain), the five Japanese words that describe the five stages of this lean manufacturing methodology. The methodology was first introduced by Hiroyuki Hirano back in 1985 and is widely used throughout the manufacturing industry in Japan, most notably by Toyota.

5S is mainly focused on removing clutter in the workplace (i.e., manufacturing plant) to ensure a safe, efficient, and productive workplace.

The 5S methodology, as the name suggests, consists of five key steps, each designed to improve manufacturing organization, safety, and efficiency: 

1. Seiri (Sort): identifying, sorting, and removing unnecessary items in the workplace. Items that are broken/damaged, duplicates, and items that are no longer useful are removed, with the objective that only necessary items are present in the workplace, eliminating clutter. 

1. Seiton (Set in Order): organizing the remaining items in a way that is organized, efficient, and accessible. This includes labeling and arranging the items in a logical order, and putting them in a designated storage area to ensure they are easy to access. The objective of this step is to ensure all useful items are easy to find and use whenever they are needed.

1. Seiso (Shine): cleaning and maintaining the workplace (until it “shines”) to ensure it is 100% free of clutter and also to ensure workplace safety. This step includes

regular maintenance of equipment, scheduled cleaning of work areas, and more. The objective of this step is to ensure the workplace is organized, clean, and free of hazards. 

1. Seiketsu (Standardize): creating standard operating procedures (SOPs) to standardize the manufacturing processes. It may also include creating guidelines for maintaining equipment and workplace environment and conducting regular audits to ensure compliance with relevant regulations. The goal is to ensure a consistent workplace where everyone is following the same, standardized procedures.

1. Shitsuke (Sustain): this step involves establishing the 5S methodology as a sustainable part of the company culture. This includes providing onboarding and regular training to employees, setting up systems to measure progress, and conducting audits to ensure compliance. The goal of this step is to ensure 5S is a part of the manufacturing company’s culture and should be included in the company’s performance metrics. 

Benefits of 5S as a Lean Technique

Implementing 5S methodology in manufacturing can provide the following benefits: 

1. Improved efficiency: 5S helps remove workplace clutter, ensure the manufacturing plant is efficient, reduce waste, and streamline manufacturing processes. Ultimately, all these will result in increased efficiency and productivity.

1. Improved safety: 5S ensures the workplace is clean, organized, and free of potential hazards. These can effectively reduce the risk of workplace-related injuries and accidents in the manufacturing plant.

1. Increased product quality: By cleaning and organizing the workplace to ensure a productive and safe environment, the 5S methodology helps the manufacturing company to focus solely on producing the products with the highest possible quality standards. 

1. Increased employee morale: the clean and well-organized workplace as the result of 5S implementation will lead to improved employee morale, workplace experience, and satisfaction. All of these will ultimately result in a lower turnover rate and higher productivity.

1. Improved cost-efficiency: the implementation of the 5S methodology can help manufacturing companies reduce unnecessary expenses, resulting in significant cost savings.

How to Implement 5S Methodology

The implementation of 5S in manufacturing will typically involve the following steps:

1. Establish the 5S team

The first step in implementing 5S is to establish a team who will be responsible for leading the initiative. This team ideally should be cross-functional (should include representatives from different departments and different levels), to ensure objective and holistic feedback, as well as to ensure buy-in and participation from all levels and all departments of the organization.

1. Conduct an initial assessment

Assess the current state of the workplace (i.e., the manufacturing plant.) 

This may include identifying sources of waste, potential hazards, and bottlenecks/inefficiencies. All work areas should be thoroughly evaluated, and the 5S team should document all their findings.

The result of this assessment should form a foundation for developing a 5S implementation plan to address all the identified issues, as we’ll cover in the next step.

1. Develop an implementation plan

Based on the result of the assessment, we can start developing a detailed 5S plan. 

Discuss how to implement each of the 5S steps: Seiri (Sort), Seiton (Set in Order), Seiso (Shine), Seiketsu (Standardize), and Shitsuke (Sustain) depending on the current state of the manufacturing plant. 

The plan should include schedules/timelines, roles and responsibilities, and lists of specific actions required for the implementation. 

1. Implement the plan

Implement the plan, starting with the first step (Seiri/Sort), and working through each of the remaining steps to the last step (Shitsuke/Sustain). This may involve: 

1. Sorting through items
2. Establishing storage areas
3. Plans for cleaning and organizing different work areas
4. Developing SOPs and guidelines for maintaining the improvements
5. Review and audit the implementation

To ensure that the 5S implementation does improve the workplace environment and manufacturing efficiency, and to ensure the improvements made are sustained over time, it’s critical to conduct regular audits. 

Schedule regular reviews for the workplace to ensure that it remains clean, optimal, and efficient. During these audits, try to also identify inefficiencies and areas for further improvement. 

1. Ongoing training

To ensure the implemented 5S methodology remains part of the manufacturing company’s culture, it’s critical to provide ongoing support and regular training to employees. You may also consider establishing policies and training employees on how to maintain regular communication on progress.

Establish a recognition program so you can formally appreciate employees who make significant contributions to the 5S initiatives. 

3. Value Stream Mapping (VSM)

Value Stream Mapping or VSM is a lean manufacturing technique that was initially used by the Japanese carmaker Toyota, back in the 1970s, or some say even earlier in the 1940s.

The focus of VSM is to analyze and optimize the flow of information and resources (i.e., materials) required to manufacture a product until it’s ready to be delivered to customers.  The key characteristic of VSM is the visual representation of the whole workflow from customer order to manufacturing to delivery.

This visualization of workflow is typically achieved using a series of symbols and shapes, and some of the common ones are:

1. Process box: the process box represents a specific process or activity in the value stream

1. Material flow arrow: represents material flow or flow of products in the process

1. Information flow arrow: represents the flow of information, such as instructions, order, files, or data 

1. Inventory box: represents the amount of stock/inventory at the specific point in the workflow

1. Kaizen burst: a lightning-bolt-shaped symbol, represents a continuous improvement opportunity

1. Customer icon: represents the end customers who receive the end product or service at the end of the workflow

1. Supplier icon: represents an external supplier of products or materials 

allows the team to see the big picture of the manufacturing process, including all the steps and actions involved, as well as inefficiencies, bottlenecks, and areas of waste.

Since its introduction, VSM has been widely adopted by many businesses and manufacturers across many different industries. 

Benefits of Visual Stream Mapping

By creating a visual representation of the current state and future state of the manufacturing processes, the manufacturing company can analyze and optimize its “value stream,” the flow of information and materials required to bring a product to customers. By doing so, VSM can provide these benefits:

1. Identify waste and inefficiencies: visualization of the whole workflow through VSM helps manufacturers identify areas of waste, bottlenecks, and inefficiencies in the process. This may include areas of overproduction, inefficient waiting time, excess inventory, overprocessing, defects, and more. The manufacturer can then use this information to eliminate the identified issues.

1. Improving information and materials flow: VSM helps the company streamline the flow of information, materials, and products through the manufacturing process. Streamlining the process flow will ultimately result in reduced lead times.

1. Enhancing production quality: by identifying potential causes of defects, VSM can help to improve the quality of manufactured products. VSM can facilitate the implementation of quality control measures and mistake-proofing systems, preventing defects and reducing the chance of reworks while meeting the customers’ demands.

1. Enabling teamwork and communication: the ideal implementation of VSM should help enable communication and collaboration among team members across different departments and levels by promoting transparency.

1. Facilitating continuous improvement: VSM can help identify current and future opportunities for improvements, engage employees and help build a culture of innovation and problem-solving.             

How to implement Value Stream Mapping

We can implement VSM in the following steps:

1. Select a process: select a process (or a specific product going to be manufactured) to map with the VSM. You may choose the most important product for your business/your customers, or choose a product that has shown efficiency issues.
2. Create a current state map: assess the product’s/process’s current state and create a current state map. This map should represent the current flow of information and materials that happened during the manufacturing process for the product. Map the current process from the point of customer order to preparation to the actual manufacturing to finally the point of delivery. Make sure to accurately identify and list all the steps and activities involved in the process.
3. Analyze the current state map: analyze the created current state map to identify bottlenecks/inefficiencies, areas of waste, and opportunities for improvement. Also, consider whether there’s any overprocessing, non-optimal waiting time, and excess inventory within the process.
4. Develop a future state map: based on the analysis results of your current state map, start developing a future state map, which will represent the desired optimal value stream flow in your manufacturing process. Identify possible solutions to tackle the issues identified in the current state map and put these solutions on the future state map.
5. Implement: Implement the future step map and make the planned optimizations/changes to the actual manufacturing process. This may involve radical changes to the plan’s layout, investing in new equipment, changes in staffing, and changes in SOPs.    
6. Evaluate and monitor: Evaluate whether the optimizations made through VSM have improved the process. Make the necessary adjustments if necessary, and if improvements have indeed been achieved, take the necessary steps to ensure the improvements are sustained. Conduct regular audits and ensure the team is following the new SOPs. 

4. Six Sigma

Six Sigma is another popular lean manufacturing methodology that was developed by Motorola in the 1980s. It is especially focused on eliminating defects and improving product quality. The name “Six Sigma” itself comes from a statistical concept. In a normal statistical distribution of data, 68% of the data would fall within one standard deviation of the mean, 95% would fall within two standard deviations, and 99.7% mean three standard deviations. 

Six Sigma’s aim is to improve product quality so that it falls within six standard deviations of the mean, a very high-quality level of 99.99966%, or only 3.4 defects per million opportunities. Thus, the name “Six Sigma” represents an ideal of achieving a very high level of quality, nearing perfection, that is difficult but not impossible to achieve.

Today, Six Sigma is widely adopted by many enterprises, including Bank of America, Ford, and General Electric. 

Benefits of Six Sigma

Six Sigma uses data analysis, statistical techniques, and problem-solving methodologies to identify and correct causes of errors, defects, and sources of waste. 

How to implement Six Sigma

The implementation of Six Sigma is based on the principle that any process–including the manufacturing process–can be measured, analyzed, optimized/improved, and controlled using statistical techniques.

1. Improved efficiency: Six Sigma can leverage statistical techniques to help improve manufacturing cycle times, reduce waste, and eliminate inefficiencies and unnecessary steps, streamlining the workflow as a result.
2. Reduce costs: By improving efficiency and reducing the chances of defects, Six Sigma implementation can result in significant cost savings for the manufacturer.
3. Increased team morale: By involving employees in Six Sigma initiatives, employees can experience increased engagement, morale, and job satisfaction. 
4. Competitive advantage: Manufacturers that successfully implement Six Sigma can gain significant competitive advantages, for example by consistently delivering high quality products while using fewer resources than the competition. 
5. Stronger bottom line: Ultimately, proper implementation of Six Sigma can result in a stronger bottom line for the company, resulting in an increased revenue and profitability. 
6. Improved customer satisfaction: Six Sigma helps to identify and eliminate bottlenecks and inefficiencies, so the company can deliver products more quickly to the customers. On the other hand, Six Sigma can reduce or even eliminate product defects, leading to increased customer satisfaction. 

Implementing Six Sigma typically involves five key steps:

1. Define: Define the opportunity for improvement or the identified problem (inefficiency, bottleneck, etc.) On the other hand, also define the objectives/goals of implementation.
2. Measure: This step involves collecting data on the process that would be improved. We can use various tools, like visual factory software or quality control software for manufacturing by LineView for this data collection purposes, and techniques like process mapping and statistical process control to measure performance. 
3. Analyze: The collected data is analyzed with statistical techniques to identify patterns, variations in the process, and especially root causes of the issue. 
4. Improve: Based on the analysis results, we devise potential solutions and implement it to improve the existing process. After implementation, the process’s performance is once again measured to identify whether it has improved efficiency or reduced defects/waste.
5. Control: The final implementation step is to control the manufacturing process to ensure that improvements can be sustained over time. Establish a control plan to monitor the improved process’s performance, and identify any ongoing issues. Re-optimize the process as needed. 

Wrapping Up

Implementing the various lean techniques we’ve discussed above in your manufacturing process can significantly improve its efficiency and productivity. Ultimately, this will result in the consistent delivery of better quality products while using fewer resources and in less time, leading to an increased customer satisfaction.

The lean techniques we’ve discussed in this guide— Total Productive Maintenance, 5S, Value Stream Mapping, and Six Sigma— are all proven techniques for improving manufacturing productivity and efficiency. By now, you should have a clearer idea into which lean technique you can implement in your business to help you stay competitive in the market.