Lean manufacturing is a systematic approach to eliminating waste in manufacturing processes. It was originally developed by Toyota executive Taiichi Ohno and focuses on eliminating the seven types of waste: transportation, inventory, motion, waiting, over-processing, overproduction, and defects. Implementing lean methods reduces waste, improves teamwork, allows for continuous process improvement, and streamlines manufacturing from start to finish.

1. LEAN MANUFACTURING
What is it? Why is it important?

2. WHAT IS LEAN
MANUFACTURING?
• Definition: Lean Manufacturing is a systematic method for the
elimination of waste ("Muda") within a manufacturing system.
Lean also takes into account waste created through overburden
("Muri") and waste created through unevenness in work loads
("Mura"). Working from the perspective of the client who
consumes a product or service.

3. WHAT IS LEAN
MANUFACTURING?
• The Lean concept was originally created by Taiichi Ohno, who was
a Toyota executive from 1912-1990. Ohno san was the first to
identify the seven types of Muda.
• John Krafcik developed the term Lean Manufacturing- using it in
his article “Triumph of the Lean Production System” that appeared
in a 1988 MIT Sloan Management Review.

4. THE SEVEN MUDAS
Transportation Inventory
• Movement of materials
from one location to
another
• Adds zero value to the
product
• All raw material, work in
progress, or finished
goods have a cost
• Inventory increases the
companies overall costs
• Inventory contributes to
many other wastes

5. THE SEVEN MUDAS
Motion Waiting
• Motions are movements
of man or machine
• Wasteful motion costs
time and money
• Waiting disrupts the flow
of information and
product
• Causes down time and
critical decisions to be
delayed

6. THE SEVEN MUDAS
Over-Processing Overproduction
• Use of inappropriate
techniques or oversize
equipment
• Working to tolerance
levels that are too tight
• Procedure not required by
customers
• Creates an issue with
storage
• Out dated or obsolete
product
• Disguises many other
problems within a
company

7. THE SEVEN MUDAS
Defects
• Defects waste time, money and resources
• Defective products require rework or replacement
• Creates unwanted paperwork and could lead to potential
customer loss

8. Removal of Waste
Build Team Cohesion
Continuous Improvement
Streamline Manufacturing Process
WHY LEAN?

9. WHY LEAN?
Removal of Waste
• With the removal of waste, a manufacturing
company has the chance to eliminate time spent
on avoidable or redundant tasks

10. WHY LEAN?
Build Team Cohesion
• All departments in a manufacturing company must
recognize that there needs to be change in order
to accomplish company wide goals
• Using Lean Manufacturing techniques builds
teamwork and cooperation

11. WHY LEAN?
Continuous Improvement
• One of the driving factors of
Lean production is the opportunities
it creates to constantly change and
become more efficient
• The Kaizen program is a great way to not only
involve everyone in the organization, but also
improve upon current operations

12. WHY LEAN?
 Streamline Manufacturing Process
• Effective processes are created and
the manufacturer is able to work at its
full potential
• This results in reduced manufacturing costs
and increased speed to customers

13. REVIEW
• Lean manufacturing is a systematic method for the elimination of waste
("Muda") within a manufacturing system
• The Lean concept was originally created by Taiichi Ohno
• The seven Muda are Transportation, Inventory, Motion, Waiting, Over-
Processing, Overproduction, and Defects
• The implementation of the Lean systems reduces Waste, builds Team
Cohesion, opens the door for Continuous Improvement, and will over all
Streamline the Manufacturing Process from the front office to the distribution
of finished product