Lean Manufacturing is a production philosophy focused on minimizing waste and maximizing value for the customer using fewer resources.
It originated from Toyota Production System (TPS) in Japan and is now widely used in various industries across the world.
π― Core Idea:
“Do more with less β less time, less space, less effort, less materials, and less cost β while delivering exactly what the customer wants.”
π§Ή What is “Waste” in Lean?
In Lean, waste = anything that doesnβt add value to the customer.
The terms Muda, Mura, and Muri come from Lean Manufacturing, particularly the Toyota Production System (TPS). Together, they represent the three main types of waste that Lean aims to eliminate.
π§ The 3Ms of Lean: Muda, Mura, Muri
Japanese Term | Meaning | Description |
---|---|---|
Muda | Waste | Any activity that consumes resources but does not add value to the product or service. |
Mura | Unevenness | Irregularities or inconsistencies in the process or workflow that cause delays, shortages, or overproduction. |
Muri | Overburden | Placing too much stress or workload on people, machines, or systems, leading to breakdowns or errors. |
π 1. Muda (Waste)
This is the most commonly known type of waste. There are 7 (or 8) types of Muda (explained earlier with the acronym TIMWOOD):
-
Transport
-
Inventory
-
Motion
-
Waiting
-
Overproduction
-
Overprocessing
-
Defects
-
(Sometimes: Unused Talent)
π§ Example: Making extra units that aren’t needed right now β Overproduction (a type of Muda).
π 2. Mura (Unevenness)
Mura refers to inconsistency in production volumes, workload, or processes.
π§ Example: A bakery gets 20 cake orders on Monday and 100 on Tuesday. This uneven demand stresses staff and leads to inefficiency.
π Effect of Mura: It causes Muda (waste) and leads to Muri (overburden).
β οΈ 3. Muri (Overburden)
Muri means pushing people or machines beyond their natural limits. It leads to breakdowns, errors, fatigue, and safety risks.
π§ Example: A single worker is asked to operate two heavy machines for 8 hours non-stop β Muri.
π Effect of Muri: It leads to mistakes (defects), downtime, and eventually burnout.
π οΈ Lean Tools & Techniques:
Tool/Technique | Purpose |
---|---|
5S | Workplace organization |
Kaizen | Continuous improvement |
Kanban | Visual signals to control workflow |
Value Stream Mapping (VSM) | Identifying waste in processes |
Poka-Yoke | Mistake-proofing methods |
Just-in-Time (JIT) | Producing only whatβs needed |