Instytut Innowacji i Nowoczesnych Technologii w Logistyce

Instytut Innowacji i Nowoczesnych Technologii w Logistyce

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Lean manufacturing

lean manufacturingLean Manufacturing is a philosophy of management consisting in the constant elimination of wastage occurring in the production processes. The stock is at the minimal level or there is no stock at all. Materials are supplied depending on the needs. High organization and the visualization of workplaces by means of the 5S rules make the employees get involved in the process of changes and improvements. The standstill of the machines during the exchanges of die are shortened to the minimum, thanks to which there is no need to produce large batches of materials.


Our advisory and consulting services concern the organization of external and internal supplies, production planning, the production itself, the warehouse of finished parts and goods, maintenance accompanied by the machine servicing.

Here are exemplary consultancy projects we offer:

  1. Value Stream Mapping (VSM) and the analysis of losses occurring in it - is a tool enabling the visualization of the course of the generation and flow of information for a chosen group of products.
  2. 5S application - consisting in the removal of unnecessary objects from the workplace (1S), visual arrangement of all necessary objects in the right place (2S), and the maintenance of the workplace in stainless cleanliness (3S). Via the standardization of performing these actions (4S), discipline and constant improvement of the methods of work (5S), a permanent system assuring order and cleanliness is created.
  3. Kaizen (meaning constant improvement in Japanese) is a management methodology which proves that small but constantly introduced improvements ultimately bring bigger effects than large reorganization of the company conducted once in w while.
  4. The implementation of the Just in Time strategy (JIT), namely of the strategy of operations enabling to produce, deliver required materials, raw materials or products exactly when they are necessary, that is in accordance with the requirements of a plan or an order. Often understood as the supplies of materials directly to assembly lines without their previous storing. It is often defined as supplies synchronized with production and they are often associated with reducing the stock levels. In fact, minimum, or even next to zero stock level is a significant quality of the JIT system. but not the only one.
  5. The introduction of the TPM programme (Total Productive Management) which is the productive maintenance of machines and equipment. In other words, it is a series of methods and organization of work consisting in the provision of the greatest possible reliability of machines and the equipment for uninterrupted production. The beginnings of TPM go back to 1951, when in Japan they started to implement Preventive Maintenance according to American standards. The measure of the TPM effectiveness is the OEE, Overall Equipment Efficiency, index - a degree of the effective use of machines measured in percentage. The global level of OEE in the manufacturing industry determines the quantity at the level not smaller than 85%.
  6. Shortening the machine and equipment changeover time based on the SMED method (Single Minute Exchange of Die). It is a series of techniques initiated by Shigeo Shingo for the changeover of machines in less than 10 minutes - in other words, in the unit processing time (single-minute). Its application brings about the radical reduction in the machine changeover times in almost every case.
  7. The Kanban Method - in a simple way enables the visualization of the material flow in the enterprise. It was developed in Japan in 1950s as a production management method. The word Kanban comes from Japanese and means a sheet of paper. In free translation is means “visible description”. The aim of the method is to control the stock and it enables almost total elimination of warehouses. The pre-production, post-production and inter-operational storage is insignificant since all materials from the suppliers are delivered just on time and the same happens in case of the shipment of the finished goods.
  8. Lean Six Sigma - a method based on obtaining data in order to achieve almost perfect quality. It assumes the identification of errors even before their occurrence. Six Sigma was created by Motorola in 1980s. It is a proven method of company management and stable growth thanks to skilful fulfillment of clients’ needs, statistical control of processes and their good organization, as well as innovativeness. Using statistical tools, the Six Sigma methodology focuses on the measurement and reduction of changeability in processes and achieving goals set by the client’s requirements. On the other hand, to a great extent, Lean focuses on the elimination of the processes and operation not bringing added value to the Client, which leads to the reduction of time and costs of the process. What has arisen from the combination of those two methodologies is Lean Six Sigma which combines the qualities of those two.
  9. The introduction of the independent machine servicing and the prevention of failures.
  10. Rationalizing the course of manufacturing processes.
  11. Optimization of external and internal supply chains.
  12. The reduction of the manufacturing costs.

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