Why Adopt Lean Manufacturing? Discover the Toyota Production System!

Lean Manufacturing is no longer a business tool used only by the company that created it: Toyota Motor Corporation.

Nowadays, several other automotive industries like its own competitor Volkswagen, the supplier of auto parts Bosch and the manufacturer of radiators Dehr, adopt several of its tools in its administrative and industrial processes.

And this mutual application does not stop here. Other manufacturing factories such as Danone and Gerdau are just a few examples. Other sectors like hospitals, banks, insurance companies and even startups around the world use tools of this system.

Lean Manufacturing's general implementation facility is based on lean principles and fundamentals that, when adjusted in each company's context, are perfectly suited to be successfully deployed in these different organizations.

It is based on this versatility of action that you will know the 5 reasons that lead every company to want to be like Toyota! Let's go?

Check out the 5 reasons that drive every company to want to be like Toyota!

1. Fast, flexible and efficient processes

The implementation of the lean manufacturing system allows the production of highly productive and flexible processes due to its available tools that comply with the concept Just in Time: The constant search for best practices that promote a smooth and efficient production flow capable of supporting customer demand.

The Value Stream Mapping (VSM), the 5S program and the Kanban and SMED techniques are just some of the tools most used in the industrial environment to increase the productivity of these processes through the elimination of waste.

2. Varied, Reliable and Innovative Products

If the first reason is the flexibility and productivity of a company's critical processes, the second is due to its ability to offer highly varied and competitive products. This is because of the consistency and autonomy that these lean processes are operated on.

The way to keep this condition alive is given by the Jidoka concept, which together with the devices Poka-Yoke, seek to ensure that the process is increasingly able to operate error proof since they are the generators of defective products.

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3. Stable and uninterrupted operational flow

As we have seen so far, Lean Manufacturing through its tools makes it possible to achieve extremely efficient processes that generate highly competitive products, isn't it? This whole scenario then becomes much more justified to implement a flow of production pulled by the customer.

The concept of Takt Time is employed to ensure that the villain of lean waste does not occur: overproduction. With this being assured, managers now have the peace of mind to deploy improvements knowing that undesirable expenses with excessive inventory, inefficient processes, and defective products are getting smaller and smaller.

4. Engaged and Motivated Employees

The employees of a lean company are considered to be the key to the success of your business. And that goes from the operating assistant to the CEO.

The cultural diversity in these companies and the relationship of integrity and respect on the part of each member in discussing their different views and opinions is extremely stimulated since different minds think better than one, don't they?

When joining a company that adopts the Lean Manufacturing culture, the new employee is usually presented to all the productive and administrative processes that contemplate the organization.

In the case of lean culture, even the most simple and operational employees can contribute their ideas of improvement and become agents of change for the company's competitive growth.

5. Constantly Stimulated Performance Indicators

An organization that has Lean Manufacturing as its management system always strives to improve: developing more competitive products, more productive processes, more effective training programs, making customers more satisfied, and so on.

The basis of this peculiar Kaizen philosophy, that through its methodology, seeks to combat all the wastes of an organization, promoting the adoption of practices and procedures more efficient and sustainable.

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