FP&M World Class Journey

Lean Manufacturing

Lean Manufacturing is the production of your product to your customer's maximum daily demand in a balanced sequenced flow process with minimal lead time using only the value-added elements of that process. All non-value added activities, such as material handling, changeover, waiting, moving, and defects manufacturing are either eliminated or minimized.

Production Lead Time

Typically 95% of all lead time is non-value added.

Lean Manufacturing is a new departure from traditional manufacturing methods. The chart below highlights the differences.

Lean Manufacturing Traditional Manufacturing
Simple and Visual Complex
Build to Demand Build to Forecast
Minimal Inventory Excessive Inventory
Focus on Non-Value Added Focus on Value Added Work
Minimum Lot Size Batch Processes
Minimal Lead Times Long Lead Times
Quality Through Process Quality Through Inspection
Value Stream Owners Departmental Supervision

The principles and concepts of Lean Manufacturing are based on the Toyota Production System, and can be applied in nearly every manufacturing environment including high volume, mixed model production as well as job shops and custom manufacturing. Flow Enterprise Process Management extends this approach throughout the organization to other business processes such as Order Processing, Distribution, etc.