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Lean Production 
Pfeil

Process Optimization - Lean Production  

Continuous improvement leading to a lean company

The Lean Philosophy minimizes wastage - in terms of time, work-in-process and rejects - in all areas along the value creation chain. No matter if it’s about a logistics concept for the entire production or the optimization of a defined work area because wastage occurs in all process steps. By a consistent implementation of the Lean Philosophy, this potential can be identified and developed for enhancing efficiency. The result is a cost reduction and a simultaneous enhancement of manufacturing efficiency coupled with an increased quality.
Good reasons for Lean Production 
  • Only continuous improvement leads to sustainable success
  • In most cases the potentials can be activated with only little investment
  • Enhancement of manufacturing efficiency
  • Reduction of costs incurred by work-in-process and stock keeping
  • Avoidance of rejects and rework - improvement of quality
  • Involvement of employees and a high degree of implementation in the workshops
PfeilLean Production Tools 
  • CIP – continuous improvement process
  • SMED – workshops for set-up time reduction
  • TPM – effective machinery by preventive maintenance
  • 3S/ 5S – cleanliness and orderliness at the workstation
  • Pull principle
  • One piece flow
  • Kanban / Supermarket / Just in time – wastage minimization in logistics
  • Poka Yoke – error prevention in the manufacturing process
  • Value stream mapping – design of lean processes


pdf
Glossary, 270 KB
Glossary Lean Production
PfeilIdentification and avoidance of wastage 


Avoiding wastage
The 7 types of wasting  Avoiding wastage 
  • Machine downtime
  • Overproduction and transport
  • Searching tools and parts
  • Rejects and rework
  • Idle times
  • Organizational deficits in the work process
  • Unused know-how of the employees
In all manufacturing processes the share of adding value is relatively low. Most of the time is spent in wastage and support processes (e.g. set-up). Lean Production eliminates this unnecessary performance and reduces times for support performances. The issue is not to work more - but to work efficiently!
 


Improvement Activities
Logistics  Project, Workshop, CIP 
Particularly in the field of logistics action must be taken. Major effects can be achieved by a
changeover in the production from "Push" to "Pull", a reduction of batch sizes and an
implementation of self-controlled loops such as (e.g.) kanban. The supermarket / minimarket as well as the separation of value creation from logistics enhances the efficiency significantly.

The improvement activities according to Lean Production must not necessarily take place in a
defined order of magnitude or within a specific framework. Depending on the scope, the
improvements are implemented in a project, workshop or employee CIP (continuous improvement process).
 

 
 
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SCHULER
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Karl-Berner-Strasse 4
72285 Pfalzgrafenweiler
Germany

Tel.: +49 7445 830-0
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