Lean Manufacturing is a methodology primarily focused on reducing waste and improving efficiencies. Similar to Toyota Production System (TPS) developed by Toyota, these processes and standards have transformed the supply chain in the automotive industry with focus on the maximum efficiencies and quality of every system within an operation.
The principles and practices applied properly eliminate waste, enhance product quality, and improve efficiency.
Lean Manufacturing in the Automotive Industry:
Elimination of Waste (Muda):
In the automotive industry, waste can take many forms. Kaizen utilizes continuous improvement initiatives that focus on eliminating waste and optimizing inefficiencies at all levels of production.
Continuous Improvement (Kaizen):
Small incremental changes harmonize all systems. All are encouraged to participate in problem solving and process improvement projects.
Just-in-Time (JIT) Production:
Inventory Management and Supply Chain Coordination provide critical balance in supply and demand by producing uniform, quality parts and finished goods through the optimization of materials and time.
Standardized Work:
Quality in production is a result of standardized processes. Lean standards and practices provide consistency in production, improved quality, variability reduction, and a well-trained workforce.
Through the implementation of these concepts and processes, the automotive industry has seen consistent improvement in product quality, enhanced customer satisfaction, improved safety, and a stronger position in the market.
These principles and practices have been so effective within the automotive industry that they are now being utilized in manufacturing for other industries globally.