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A set of extremely efficient production techniques that were first introduced and implemented by Japanese companies, notably Toyota, are called Lean Production techniques. Lean Production first came to the notice of all in the 80s and 90s. The techniques provided a judicious mix of utilizing both individual quality as well as mass production methods. Lean Production techniques emphasizes on reducing waste while increasing customer value and product quality. These techniques with the astounding results that they have yielded are often considered the largest change brought to production after Henry Ford’s mass production methodology in the last century.

As mentioned earlier, this system combines the best of quality of individual craftsmanship along with the low cost benefits of mass production. Mass production or assembly line production methods get extremely repetitive, boring and mundane. Thus, worker productivity may dip. Using lean production methods, workers are organized in groups where they do tasks assigned to entire groups. The tasks are given in such a way that they are not very monotonous and special emphasis is made to keep worker engagement high.
Lean Manufacturing from TXM

Another important aspect of lean production is efficient inventory management. As a matter of fact, it is preferred that no inventories are maintained. The workplace is organized in such a manner so that all the raw materials and tools required on a daily basis are within easy reach. The workplace is kept clean, organized and clutter free. Thus, it is more ergonomic and systematic to work in. This reduces production delays and smoothens production cycles. Special emphasis is laid on detection and correction of any fault or defect immediately. In the conventional system, faulty products were placed on the side to ensure that the assembly line was not stopped. These faulty products were meant to be handled at a later stage. Yet, this approach prevented learning and encouraged pushing problems further ahead to be tackled in the future. Lean production approach ensures that each product that faces a problem is immediately attended to. This provides valuable learning that can help solve and prevent future problems of a similar nature. It also enhances worker learning and engagement. The end result is a production cycle that yields good quality error-free products every single time. This cuts on the need for keeping large inventory in store thus saving precious cost and also storage, transportation and other expenses.

Lean Consultant Job

Some may point out and rightly so that frequent stoppages may slow down production cycles. It must be recognized that this will just happen a few times in the beginning but with enhanced learning, the problems can be ironed out easily and future stoppages with respect to the same problem can be completely avoided.

Thus using trustworthy and effective lean production methodology, economies of scale can be achieved along with high quality and reduced waste.

DO you ever want your production to grow? You need a lean consultant to help you. Consult Total Excellence Manufacturing for the procedure. The company has the best list of professional lean consultants that have been working extensively to various large companies to improve their production. You too can have them. Check them out through the TXM link.
In times when recessionary pressures are weighing down the bottom lines of even the most robust of organizations, lean management as a philosophy can help increase customer value and bring down costs. In short, you can achieve more and better quality from similar resources by cutting down waste. Lean management is considered to be very effective especially in manufacturing organizations. Though, it has been replicated with great success even across non-manufacturing organizations.

Let us see some ways in which lean management techniques can help cut costs for companies:

Cut down waste: Some of the important lean tools like 5S, better production scheduling, low inventory, and tighter inventory management help in cutting down hidden wastes that pull up the cost of production. Organizing the workplace and training the employees better can attain improved production efficiency.

Moreover, you should pay attention to catching every defect right at a nascent stage instead of allowing them to pile up till the last stage of production that and eventually holds back the production schedule. Training of the workforce and motivating them is an equally important step which ensures that waste is kept to the minimum. It is important to define the meaning of waste and value for your employees so they are able to enhance customer value and bring down waste.

Continuous review: Lean management principles ensure that processes are reviewed periodically to catch any discrepancies. This helps in spotting deviations early on and in taking corrective steps to rectify the situation. This regular reviewing also helps to stay more in tune with the changing business environment thus enabling a sharper and faster reaction to minor issues.

Increase value: It may seem surprising but cutting down waste actually helps increase customer value and also improves quality of the products. This is very different from the understanding that cutting costs always cuts down quality.

Thus, in order to put your organization on the path of low waste, implementing lean management principles is definitely a good start. Hire experienced and reputed lean consultants to help in smooth implementation of lean in your organization. Remember, you will be successful in implementing lean properly only if the people as well as the systems are simultaneously modified.

Lean management is all about the right approach of asking the right questions. It is the method that enhances customer value and product value while keeping the waste out. This really is the right way to enhance quality and make bottom lines robust!

Do you want to learn more of lean management? Contact Total Excellence Manufacturing at this number +61 3 96078241.

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Are you looking for qualified lean consultant? The search may not be that easy but I guarantee, it’s not that very hard. Many people these days have already engaged into serious understanding and studying of lean manufacturing and management, allowing them to get full exposure to the concepts and application of lean. Boeing, Toyota, Mitsubishi and all big time appliance, car and electronic companies are backed up with lean experts that have been closely monitoring every processes until the produced products are in perfect shape to get into the market in less time, with less waste. Have you ever thought about how millions of money are invested to manufacturing companies and returned just as excessively much? Do you wonder why White-Westinghouse was able to operate for more than 20 years and still kicking the market with high sales?


Because more than the intelligent people to maintain the sales, there have been lean consultants behind these companies to secure the supervision and management in the manufacturing operations. You need lean consultants in your production business or expect it to never last. Remember that common employees would need leaders to direct them on each of the established procedure of your company for a smooth and timely process. If you have a weak lean management, you would likely fail no matter how competent your upper system management may become.
So what are the top qualifications of a reliable and qualified lean consultant? Read on.

1. Your lean consultant must have years in operational and general management roles and should have an extensive experience in both project management and process improvement. Don’t do a mistake on this – allow only the right person to get into your premise.


2. Your lean consultant must be able to present proofs of his or her previous work.
He must have the papers to prove that he has been into trainings and have established a successful career path before he gets out of the circle. He must also have an impressive record of lean manufacturing experience in industries he has worked on before.

3. Your lean expert must have a deep understanding of lean thinking and should have the ability to explain and apply the concepts of lean in many different processes.
As lean concept may well be applied to various applications, your lean expert must have the best qualifications to get this right on track.

4. Your lean consultant must also possess a good working relation to everyone he has worked with – with work ethics and value. He must have the winning attitude towards other employees and towards his work. He must be able to understand the issues of lean production and must be able to address them with confidence without getting himself and the team into problems.


These are just among the top qualifications of lean consultant that you must welcome into your company. Give time to find the right one – don’t rush. Keep in mind that experience is the most important thing – the contributions he can do to benefit the entire industry.

Of course, a well-versed and certified lean consultant demands a high pay. But this shouldn’t discourage you as their value and part to your industry can repay you a hundred fold. Choose carefully.

If you are interested to knowing some of the best lean consultants in Melbourne – I will share you the certified lean experts of TXM – Total Excellence Management. Click the link to read their profile and work.

Major Targets of Lean Production

If you are aiming to boost your production then you must better get a good overview to how lean production works. Lean production promotes stability and encourages your labour to do better in organizing and securing your goods to prevent damages and wastes. Over time, lean production has helped keep many industries function into its fullest while improving production output. Generated goods and products increased with proper lean management. This success has reached many manufacturing sites all over the world including Australia and USA and this is now your time to adapt to the advantages that lean manufacturing provides.

Here are the targets of lean production:

1. Lean production promotes continuous improvement that gears up employees to constantly involve their selves in making improvements to quality. It is vital to both large and small manufacturing companies to secure a quality results in their goods and services. Lean production strengthens employee’s productivity while keeping waste minimal. With proper implementation or execution of lean production, you can secure a more productive and effective employees.

2. Just-in-time production secure that materials are received just as they are needed. This eliminates the need to maintain large stocks of products. With just-in-time production, you are guaranteed that every order is utilized, that no stocks are disregarded and that waste is minimized. You can enhance just-in-time production through getting expert lean consultants that are trained to inspect and maintain your production quality and pace.


3. Time based management is another lean production target that aims to minimize the time wasted in the production processes. To master time based management, you need a multi-skilled and flexible workforce to secure that every process is completed within time. With strict compliance to time, each production procedures are done without delay whilst getting high quality outputs.

4. Another lean production concern is the total quality management which is a quality assurance ideal where all of the workers have a responsibility of getting it “right first time”. This diminishes the production mistakes that lead to wastes. With proper implementation of TQM, production remains fast with higher quality and less wastes.

You may not have well-understand the concepts of lean production but it is never too late to get into its full meaning. With the goal to eliminate waste and maximize time in manufacturing and production, you are on the right path to understand the concepts and apply the functions of lean production.

If you want to know more of lean production, visit TXM or talk to expert lean managers that are all prepared to help you get the basics of lean management. If there are ideas we missed on this article, you can suggest them to us through:

Help us get better – send us your feedback through dropping us a comment. Let’s help one another in understanding lean production.

5S Defined and Explained

5S describes how to organize a workspace for efficiency and effectiveness by identifying and storing the items used, maintaining the area and items and sustaining the new order. Many people have mastered this systematic approach to apply on their own business. The decision-making process normally comes from a formal discussion among employees and manager regarding standardization of how they should perform the work with less mistakes but more quality.

Let’s take a look at each of the S of 5S:

1. Sorting. Everyone must have known what sorting is. In manufacturing industry, sorting term suggests the same meaning – eliminating all the unneeded tools and parts and keeps only those important and valuable. Keep only essential items and eliminate what is not required or simply prioritizing things per requirement and keeping them easily accessible to employees in need. Everything else then is categorized for use or thrown away.

2. Straightening.
This simply implies arranging work, the employees, parts and instruction in a way that the work flows free of waste. Straightening is by far the most misunderstood and incorrectly applied S. It has also been accountable for several lean transformations failing to produce the results and benefits needed. If managers would lean to apply straightening concept correctly, this concept would eliminate the majority of non-value added time. It would also allow the rest of the zero defect philosophy to work. For straightening to work best, you must have to observe an orderly flow of process in managing your resources.


3. Systematic cleaning.
This concept points to cleaning the workspace and all the equipments, keeping them clean and sparkling as much as possible and well-organized. At the end of each working day, the workspace is free of clutter and everything is taken back to its proper place. This concept also assures that the place is ready for the next employee assigned to work in the area and that the order is kept.

4. Standardize.
This concept ensures that same procedure and setup is observed throughout operation to promote fast results and quality exchange of goods and information between employees. Without standardization, business is bound to fail as output turns below par.

5. Service. This step ensures complete submission to rules and procedures to prevent backsliding. Ensuring discipline adherence to the regulations promote fast turnover of production and motivated workers.
What are the additional S’s?

Additional 5’s include SAFETY, SECURITY and SATISFACTION and they are all defined and explained by experts of TXM. Visit Total Excellence Manufacturing to read more about 5s and the additional S.

CLICK HERE to read more.