How can you implement lean manufacturing process design like Toyota?

1 Identify value

The first step in lean manufacturing process design is to identify what value means for your customers and your products. Value is the benefit that your customers are willing to pay for, and it should guide your decisions on what features, functions, and specifications to include or exclude in your products. To identify value, you need to understand your customers' needs, expectations, and preferences, as well as the market conditions and the competitive landscape. You can use tools such as value stream mapping, customer surveys, and benchmarking to identify value and eliminate any activities or resources that do not add value.

2 Optimize flow

The second step in lean manufacturing process design is to optimize the flow of materials, information, and people through the production process. Flow is the smooth and uninterrupted movement of value-adding activities from the start to the end of the process, without any delays, bottlenecks, or defects. To optimize flow, you need to eliminate any waste that disrupts or hinders flow, such as overproduction, inventory, waiting, transportation, motion, overprocessing, and defects. You can use tools such as kanban, pull systems, just-in-time, and cellular manufacturing to optimize flow and synchronize the demand and supply of materials and information.

3 Implement pull

The third step in lean manufacturing process design is to implement pull systems that regulate the production process based on the actual demand from the customers. Pull systems are the opposite of push systems, which produce based on forecasts or schedules, regardless of the customer demand. Pull systems ensure that you produce only what is needed, when it is needed, and in the amount that is needed, avoiding overproduction and inventory. You can use tools such as kanban cards, supermarkets, and signal systems to implement pull and trigger the production or delivery of materials or products based on the customer orders or consumption.

4 Ensure quality

The fourth step in lean manufacturing process design is to ensure quality at every stage of the production process, from design to delivery. Quality is the degree to which your products meet or exceed the customer expectations and requirements, and it is essential for customer satisfaction, loyalty, and retention. To ensure quality, you need to prevent, detect, and correct any defects or errors that may occur in the production process, as well as continuously improve your processes and products based on feedback and data. You can use tools such as poka-yoke, jidoka, andon, kaizen, and quality circles to ensure quality and empower your workers to stop, report, and solve any quality problems.

5 Embrace change

The fifth step in lean manufacturing process design is to embrace change as an opportunity to learn and improve your processes and products. Change is inevitable in the dynamic and competitive business environment, and you need to be able to adapt and respond to the changing customer needs, market conditions, and technological innovations. To embrace change, you need to foster a culture of continuous improvement, innovation, and learning, as well as involve your workers, suppliers, and customers in the process of change. You can use tools such as PDCA, A3, and hoshin kanri to embrace change and align your goals, actions, and results with your vision and strategy.

6 Respect people

The sixth and final step in lean manufacturing process design is to respect people as the most valuable asset and the source of improvement and innovation. People are the ones who design, operate, maintain, and improve the production process, as well as interact with the customers and suppliers. To respect people, you need to provide them with the necessary training, tools, and resources, as well as empower them to make decisions, take ownership, and collaborate with others. You can use tools such as 5S, standard work, visual management, and team building to respect people and create a safe, clean, and efficient work environment.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?