Definition: Lean manufacturing is the process of analyzing the flow of information and materials in a manufacturing environment and continuously improving the process to achieve enhanced value for the customer and the enterprise.  Lean focuses on the reduction of waste wherever it may be found.

The following are seven types of waste associated with manufacturing:

1. Excess inventory (WIP and over-production due to quality concerns).
2. Queue time (waiting for the next operation - stretching lead time).
3. Processing (failing to identify the optimum process).
4. Material handling (wasted time and cost in moving parts to and through processes).
5. Fixed assets (excess machines, fixtures and tooling caused by a poor processing strategy).
6. Defects (scrap and rework due to lack of precision or multiple handlings).
7. Direct and indirect labor (optimum processes must identify the minimum labor input).

Opinions differ as to whether lean manufacturing means strict adherence to the Toyota Production System model, or whether any combination of process improvements that address these goals is also lean.  The articles highlighted in the left panel discuss these issues more completely, and you are invited to review them at your convenience.

The benefits of embracing lean principles are difficult to ignore:

• Reduce scrap by up to 90%
• Reduce setup times by up to 90%
• Reduce lead times by a factor of four (or more)
• Improve productivity by up to 50%
• Improve quality by up to 75%
• Increase inventory turns (freeing up capital)
• Increase cash flow
• Compete in existing and developing markets
• Improve customer satisfaction (last – but not least).

Mazak embraces lean manufacturing on many levels.  Our products incorporate advanced technologies that allow for affordable, productive multi-machine lean cells (see Nexus Series), and the industry’s largest range of multi-tasking machines for combining a host of varied operations onto one machine.  It’s what we call Done-In-One.  And all of these products can be integrated with flexible automation.

We also embrace lean manufacturing in our own factory in Florence, KY.  Unique to our machine tool business, it is called Production-On-Demand.  It features a build-to-order “pull” system, replacing our previous batch processing, and delivers us many benefits.  An article is included at left describing POD in greater detail.

Mazak operates seven Technology Centers throughout North America.  One of the prime purposes of these centers is to work with our customers and supplier partners to develop lean processes.  Customer parts are evaluated from a clean sheet of paper to apply any and all innovative ideas for cost reduction under lean guidelines.  Please link to our Technology Centers from our home page to learn more.

Highlighted below are some Mazak products that contribute to lean manufacturing.  Simply click on the photos to learn more about each family.  Then, please contact us for an evaluation of your current processes.