Lean Production


Traditional mass production methods can create problems, which leads to
The main problems are:

Employee boredom and low morale - a problem of doing the same thing
all the time
Equipment failure – equipment breaks down
Equipment becomes outdated

Businesses have tried to make production more efficient by becoming more
flexible” and “lean”.

Lean production aims to eliminate all forms of waste in the production
and so produce more by using fewer inputs.

There are several forms of waste that lean production aims to eliminate:-

Waste from materials
Waste of worker’s time and effort
Waste of floor space
Waste from defective products (poor quality)

There are several popular
management techniques that have been
developed to help achieve “lean production”. The three most popular are:

Cell production
Kaizen (continuous improvement)
Just-in-time (“JIT”) manufacturing

Cell Production

In cell production, workers are organised into multi-skilled teams. Each
team is responsible for a particular part of the production process including
quality control and health and safety. Each cell is made up of several teams
who deliver finished items on to the next cell in the production process.

Cell production improves motivation (team spirit and added responsibility
given to cells) and workers sharing their skills and expertise.

Kaizen (Continuous Improvement)

Kaizen means “continuous improvement” and implies a process where the
overall progress
and gains in productivity within a firm, come from small improvements by
workers being made all the time.

Just-in-time (“JIT”) Production

JIT means that stock arrives on the production line just as it is needed. This
minimises the amount of stock that has to be stored (reducing storage