Lean manufacturing is one of the hot topics for waste reduction and manufacturing in large quantities all around the world. It is one of the most sought out manufacturing process to reduce ingrain efficiency in the manufacturing processes and reduce wastes (MUDA) at the same time. It is also widely recognized as a proven method to improve labour productivity as well. In this blog of our transformation Tuesday, we will enlighten our readers with tools to reduce the amount of waste in their production processes which will ultimately help them in beaming their steps towards lean manufacturing.

1. The Five S Program
We have earlier also talked about a lot about the benefits of 5S tools and methodology in implementing lean principles in any manufacturing process at any manufacturing facility. The 5S program provides a detailed and scientific framework for workplace management ensuring better efficiency and higher productivity. Below is a detailed version of 5S program.

• Sort – It is one of the primary steps to reduce waste in any manufacturing process. It includes removal of any non-value adding activities by running various sorting activities.

• Set in Order – Keeping things in order ensure a better and smooth operation of various processes involved in a manufacturing process which is essentially required for better productivity. It also helps the manufacturer in keeping the quality of the product to an optimum level.

• Shine – Shine is basically about keeping the workplace clean and organized to assist in the various system controls and tools in keeping the wastes to the lowest levels possible.

• Standardization – Operating under a given set of standards is highly important in any manufacturing facility. It is very important that the equipments used in process and the manpower involved is highly inclined towards the standards set and operates under the same.

• Sustain – The last step in the Five S program is to sustain all the above-discussed steps for a successful implementation of the Five S program at a manufacturing facility. It also includes performing regular audits, training the workforce and various other steps to keep the processes on the track and holding them from pivoting to any other direction.

2. Ingrain 3Ms
Ingraining 3Ms (Muda, Mura, and Muri) in any waste reduction process is quintessential for the success of the process.

• Muda – Muda stands for waste and what it conveys is reducing the amount of waste to almost a negligible quantity in the final product of the manufacturing process.

• Mura – It stands for balancing out the imbalances in any production process thus making it more optimized and facilitating in reducing waste products.

• Muri – Muri refers to stress which arises due to working rigorously for long hours. This must be kept under control to ensure a smooth flow of processes across the facility.

Lean manufacturing is the need of the hour of today’s competitive manufacturing industry. Ingraining it will not only help in reducing wastes but will also assist the manufacturers in saving time and money, reducing the defects, better inventory management, logistics, controlling overproduction and in many other aspects of manufacturing. Its benefits are countless and quite profound when implemented in an organized and efficient manner.

Written & Compiled By Faber Kishlay & Faber Mayuri