Lean Manufacturing

LEAN is a production practice that considers the expenditure of resources for any goal other than creation of value for the end customer to be wasteful, and thus a target for elimination.

Lean is centered on preserving value with less work.  Lean manufacturing is a management philosophy derived mostly from "Toyota Production System" (TPS) in  the 1990s. TPS is renowned for its focus on reduction of original "seven wastes" to improve overall customer value, but there are varying perspectives on how this is best achieved.  One of the lean "tools" are Value Stream Mapping, 5S, Kanban and Poka Yoke.

Lean manufacturing is a variation on the theme of efficiency based on optimizing flow. Irregular production with ups and downs in production levels would be considered waste.  Some practitioners have combined 6 Sigma ideas with Lean Manufacturing to yield a methodology called Lean 6 Sigma.

6 Sigma Project follow two project methodologies inspired by Deming's Plan-Do-Check-Act Cycle.
These methodologies compose of DMAIC and DMADV.

DMAIC is applied on projects focused on improving existing business process.
DMADV is applied on projects to create new product of process designs.

DMAIC method has 5 phases:

• Define the problem
• Measure Key aspects
• Analyze the data
• Improve or optimize
• Control the future state process

The core of lean is founded on the concept of continuous products and process improvement and the elimination of non-value added activities. Improving the flow of material through new ideal system layouts at the customer's required rate would reduce waste in material movement and inventory. 

What is 5S?

What is Quality without continual improvement, one method to include in the improvement project will be the 5S projects.  It could be simple as housekeeping activities to more refine such as conducting monthly audit and award system. Either way it works toward achieving quality workplace.

Supermarket best place to find 5S practice

5S practice is a technique to establish and maintain quality environment in an organisation. The 5S's are a group of techniques to promote workplace organisation, ensure adherence to standards and foster the spirit of continuous improvement.

Principles/ Key Attributes
To successfully convey the message of 5S across the organisation, achieve total participation and systematically implement the practice, establishing effective quality processes as pre-requisites for good products and services, the following step-by-step approach should be adhered:

• Sort (Seiri)

The objective of sorting or organisation is to get rid of unwanted items by focussing on the core items that are needed to fulfil the requirements of the job and discard items that are not needed. This could focus on the elimination of excess inventory affecting, warehouse space, transportation, labour costs, needed items, and redundant parts, for example.

• Set in order/Neatness (Seiton)

Neatness focuses on efficiency, with the main objective being on how quickly one can get the things needed and how quickly those things can be put away. This is achieved through locating a specific place for specific items of a specific quantity, where needed.

• Shine/Cleaning (Seiso)

The objective of cleaning is to identify abnormalities and areas for improvement. This is achieved through a combination of cleaning the workplace and at the same time focusing on the identification of abnormalities or out of control conditions.

• Standardization (Seiketsu)

The objective of standardization is to consolidate the first 3 S’s by establishing standard procedures. This activity is carried out to determine the best work practices and find ways of ensuring that everyone carries out an individual activity the same ‘best’ way.

• Sustain/Discipline (Shitsuke)

The objective of discipline is to sustain improvements and make further improvements by encouraging effective use of the ‘Check-Act-Plan-Do’ cycles. This is achieved through strict adherence to current improvements and the development of an environment for future improvements.

The Impact on functional Activities
The approach embodied with 5S will effect everyone and everything within an organisation. The technique of 5S begins with a promotion plan for the sole purpose of promoting the establishment of the 5S’s. This incorporates everyone within the organisation from the highest level to shop floor level consisting of a blame-free environment. To instill all viewpoints at each level a steering committee is formulated and is responsible for the implementation of 5S.


The next stage is Awareness Training focusing on the dissemination of the 5S plan and its objectives and incorporating suggestion schemes for the ‘buy-in’ of all employees. An Internal Audit highlighting areas for improvement.

By working on 5S, company will be able to reduce tremendous amount of waste in terms of time, space, movement and cost.  5S is a great way to start on lean management, as the principles are basic and easy to apply throughout the organization.