Five core principles underly the Lean Manufacturing methodology
Focus on Processes – Lean is focused on improving processes. This can apply to any process where inputs are converted to an output. Therefore, while Lean was developed in manufacturing processes, it can equally apply to processes in sales, supply chain, human resources or finance as well as in a huge range of non-manufacturing businesses.
Maximise Value and Minimise Waste – In Lean, we define value as the actions or process steps that add value for the customer of that process. Everything that is not value is then defined as waste. Lean manufacturing methodologies focus on eliminating that waste, but also on increasing the value the customer receives in order to create competitive advantage.
Standardising the Work – A key element of Lean thinking is the idea of improving the standard. However, to improve a standard, you must first have a standard. Therefore, in Lean Manufacturing, we try to standardise every task in terms of content, sequence, timing, and outcome. When we standardise work, we increase the chances of getting a consistent quality result and also, we can measure when we have improved the standard. As well as standardising the work Lean also standardises the workplace by using 5S to create a work environment where there is a place for everything and everything is in its place, safe, clean and ready for use.
Creating Flow – A core principle of Lean manufacturing is the idea of flow. This means a process where products or services flow through every process step in a defined sequence, one by one, at the rate of customer demand. When this is achieved, we minimise the waste in the process and deliver the minimum lead time and maximum agility.
Solving Problems – In Lean manufacturing, we welcome problems as problems give us the opportunity to learn and improve the process. However Lean manufacturing specifies that we use the scientific method to solve problems and improve the process. Rather than jumping to the solution, we first identify the root cause of the problem, develop a solution, implement the solution, check the results so we know that the solution work and then lock in the new method through new standard work. We call this the Plan-Do-Check-Act method of solving problems and it is at the core of Lean Methodology.