Industrial Glossary

Definition and origins of Lean Management

Visit Lean-Management, often referred to simply as “Lean”, is a global management philosophy derived from the Toyota Production System (TPS - Toyota Production System). It is no longer limited to manufacturing, but applies to all company sectors and functions (Lean Office, Lean Services, Lean Engineering).

In-depth definition : Lean Management is a systemic approach aimed at maximizing Customer value while minimizing the use of resources. It constantly strives to identify and eliminate all types of waste (Muda) into processes, guaranteeing a smooth, frictionless production flow. Its essence is based on five fundamental principles:

• 1. Set value from the customer's point of view
• 2. Mapping the value stream (Value Stream Mapping - VSM)
• 3. Create a feed continuous
• 4. Establish the draw (Pulled Flow)
• 5. Pursuing perfection (KAIZEN).

Lean is the methodological pillar of the’Operational Excellence.

The Seven (or Eight) Wastes (Muda): The Home of Improvement

The heart of Lean lies in the fight against waste. waste (Muda), Waste is any action that consumes time and resources, but does not add value for the customer. The seven traditional wastes (with the eighth, not always included, but critical) are :

1. Defects : Errors, rejects, non-quality, requiring costly rework and inspections.
2. Overproduction : Producing more, sooner, or in greater quantity than necessary. This is the most dangerous kind of waste, because it masks the others and is the direct consequence of Flux Poussé.
3. Waiting : Inactive time for operators or machines, often linked to a Bottleneck.
4. Transport (Transport) : Unnecessary movement of products, materials or information.
5. Inventory : The accumulation of raw materials, work-in-progress (WIP) or finished products. Stock is expensive and hides problems.
6. Movements (Motion) : Unnecessary or inefficient movements by operators at their workstations.
7. Over-Processing : Doing a more elaborate job than the customer requires (e.g. polishing an invisible internal surface).
8. Non-Utilized Talent : The waste of ideas, creativity and employee skills (the eighth Muda, recognized as crucial).

The Key Tools of Lean Management for Industrial Engineering

Visit Industrial Engineering uses Lean Management to structure its optimization approach. Essential tools include :

• Value Stream Mapping (VSM) : The essential analysis tool for mapping current flows and designing future flows, distinguishing value-added from non-value-added.
• 5S : A method for organizing and tidying the workstation (Seiri, Seiton, Seiso, Seiketsu, Shitsuke), which is the basis of all standardization and safety improvements.
• SMED (Single Minute Exchange of Die) : Technique designed to reduce changeover times to a minimum to enable the production of small batches, an imperative for moving from Flux Poussé at Pulled Flow.
• Kanban : The signaling tool that makes Pulled Flow, ensuring that production is triggered by downstream demand.
• Poka-Yoke: Anti-error devices or systems to make defects impossible to commit, guaranteeing quality the first time (First Time Right).

Lean Management and Digital Transformation: The Union of Method and Technology

Lean's effectiveness is enhanced tenfold by the Industrial Digitization. L’Industry 4.0 provides tools for :

1. Precision Measurement : L’IoT enables real-time data to be collected to measure waiting times, cycle times and the TRS with an accuracy that manual lean could not achieve. This data precisely targets the areas of application of the KAIZEN.
2. Flux Plus Rapide : The systems MY and the’Artificial Intelligence (AI) can optimize flows and planning dynamically, going beyond the static capabilities of a paper-based Lean system (manual Kanban).
3. Advanced Visual Management : Digital screens are replacing whiteboards, displaying the latest KPI and alerts from Choke bolts instantaneously, facilitating rapid reaction and Root Cause Analysis (RCA).

In conclusion, the Lean Management is the strategic approach that enables companies to focus on what matters: the customer. By eliminating waste, it not only reduces costs, but above all enables us to become more agile, more responsive and to guarantee a high level of customer satisfaction. Quality constant in Series Production. It's a journey to perfection that ensures the longevity of the Operational Performance.