Key Principles of Lean Production:
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Value (Customer-Centric Approach) – Identify what adds value to the customer and focus on optimizing those aspects.
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Value Stream Mapping – Analyze the production process to identify inefficiencies and eliminate non-value-adding activities.
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Flow Optimization – Ensure a smooth, uninterrupted workflow by reducing bottlenecks and delays.
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Pull System (Just-in-Time, JIT) – Produce only what is needed, when it is needed, and in the quantity required to avoid overproduction.
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Continuous Improvement (Kaizen) – Encourage ongoing enhancements in processes, efficiency, and quality.
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Elimination of Waste (Muda) – Identify and remove waste in production, such as excess inventory, waiting time, and unnecessary movements.
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Respect for People – Empower employees, promote teamwork, and involve workers in problem-solving.
Types of Waste in Lean Production (The 7 Mudas):
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Overproduction – Producing more than what is needed, leading to excess inventory.
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Waiting – Delays in processes due to inefficiencies.
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Transport – Unnecessary movement of materials or products.
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Overprocessing – Performing extra steps that do not add value.
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Excess Inventory – Holding more stock than necessary, leading to high storage costs.
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Unnecessary Motion – Inefficient movement of workers or machines.
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Defects – Errors requiring rework or scrapping.
Benefits of Lean Production:
✔ Cost Reduction – Less waste leads to lower production costs.
✔ Increased Efficiency – Optimized processes improve workflow and reduce delays.
✔ Higher Quality – Continuous improvement ensures better product quality.
✔ Greater Flexibility – Lean systems quickly adapt to changing customer demands.
✔ Better Employee Engagement – Employees are involved in improving processes.