“Waste is anything other than the minimum amount of equipment, materials, parts, and working time which is absolutely essential to add value to the product or service.”
– Taiichi Ohno
Lean Manufacturing is an important practice focused on eliminating waste and maximizing productivity. It is quite simple: the mission is to identify activities that add value to a product or service and remove anything that doesn’t. This was not always a standard practice, and even today, countless inefficiencies and sources of waste continue to go unnoticed. These issues lead to reduced profitability, lower productivity, and missed opportunities for growth and innovation. An often overlooked yet critical component is Material Handling. As the manufacturing landscape evolves, it is crucial to continuously identify and address new areas of waste. Success lies in staying grounded in the fundamentals while embracing advancements that shape the future of our industry.
The Toyota Production System
This methodology was inspired by Taiichi Ohno and Eiji Toyoda. In the 1950s, Ohno and Toyoda visited Ford’s manufacturing facilities in the United States to study their mass production techniques. While impressed by the scale and speed of Ford’s assembly lines, they observed significant inefficiencies, including excessive inventory, disconnected processes, and high defect rates. They also noticed that workers were overburdened with repetitive tasks but underutilized in problem-solving. These inefficiencies created waste, added costs, and limited adaptability to changing customer demands.
Upon returning to Japan, Ohno and Toyoda adapted what they learned to develop the Toyota Production System (TPS). Instead of mass production, they focused on eliminating waste, as well as implementing Just-In-Time (JIT) production, and integrating quality checks throughout the process. They empowered workers to contribute to continuous improvement (Kaizen) and designed flexible systems that responded to real-time demand. This innovative approach reduced costs, improved efficiency, and set the foundation for Lean Manufacturing, transforming Toyota into a global leader.
The Toyota Production System categorizes waste into three types: Mura, Muri, and Muda. Let’s explore how these apply to material handling:
Mura (Unevenness)
Mura refers to inconsistencies in workflows, such as unpredictable demand or uneven workload distribution. Automation can address this by standardizing processes and ensuring consistent performance across operations.
Muri (Overburden)
Muri involves overburdening workers or equipment, leading to burnout or breakdowns. Automated material handling systems reduce physical strain on workers, minimize machine wear, and ensure safer working conditions.
Muda (Waste)
Muda is the most detailed category of waste, encompassing eight specific types that Lean Manufacturing aims to eliminate:
Eight Types of Muda
1) Defects: Errors in picking, packing, or shipping can be reduced with automated quality control systems. For example, barcode scanners and vision systems ensure accuracy at every step.
2) Overproduction: Producing more than what is needed increases inventory and storage costs.
3) Waiting: Delays caused by material shortages or equipment downtime waste valuable time.
4) Unutilized Talent: When employees are bogged down by repetitive manual tasks, their potential for innovation and strategic contributions is wasted. The right material handing can free workers to focus on high-value activities.
5) Transportation: Unnecessary movement of materials between facilities or within a warehouse increases costs. There are many hugely beneficial systems to optimize help routes and minimize excessive transportation.
6) Inventory Excess: Holding surplus inventory ties up capital and increases storage costs. Real-time tracking and JIT systems help maintain optimal inventory levels.
7) Motion Waste: Excessive movement by workers or machines, such as walking to retrieve items, adds no value. Ergonomic designs in material handling are ideal for eliminating unnecessary motion, saving time and increasing safety.
8) Excess Processing: Performing more work than necessary, such as redundant quality checks, wastes resources.
Lean Manufacturing Today
Today, Lean principles have expanded beyond traditional manufacturing and paved the way for industries like material handling, where technology such as tuggers carts and automation play a crucial role in driving efficiency. Automated solutions—such as robotic palletizers, automated guided vehicles (AGVs), and smart conveyors—align perfectly with Lean objectives by reducing waste, streamlining workflows, and enhancing worker safety.
The principles of Lean Manufacturing, introduced by James P. Womack and Daniel T. Jones in their book Lean Thinking (1996), provide a roadmap for businesses seeking operational excellence.
5 Key Principles of Lean Manufacturing
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1. Identify Value
Value is defined by the customer’s needs and expectations, not the manufacturer. In terms of material handling, this could mean faster delivery times, error-free operations, or reduced costs.
2. Map the Value Stream
Mapping the value stream involves analyzing all steps—from receiving raw materials to delivering finished products—to identify and eliminate non-value-adding activities. In material handling, this might include:
— Streamlining inventory movement with AGVs.
— Using real-time data from warehouse management systems (WMS) to optimize workflows.
— Eliminating redundant or unsafe manual tasks.
3. Create Flow
Ensure that production flows as smoothly as possible. Tugger carts or automated solutions like smart conveyor systems or automated storage and retrieval systems (AS/RS) can eliminate delays, minimize bottlenecks, and interruptions. For instance, AS/RS can retrieve items quickly and accurately, reducing downtime and improving overall efficiency.
4. Establish Pull
A pull system ensures production aligns with actual demand rather than forecasts. Technologies like Just-In-Time (JIT) inventory systems and real-time tracking ensure that resources are used efficiently, and waste is minimized.
5. Seek Perfection
Lean Manufacturing is an ongoing process of improvement. In material handling, this involves:
— Regularly analyzing workflows.
— Leveraging data from Internet of Things (IoT) devices to identify inefficiencies.
— Encouraging a culture of innovation and continuous improvement.
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LEAN Starts with Material Handling
In Lean Manufacturing, success often begins with efficient material handling. Autonomous transfer systems (such as powered rollers) and innovative mechanical systems such as Jtec’s mother-daughter tugger carts, play a pivotal role in reducing waste, streamlining workflows, and enhancing ergonomics.
These systems not only help identify and deliver value by ensuring materials are transported efficiently but also free up workers to focus on higher-value tasks, effectively utilizing their talent. By minimizing the physical strain of manual transport and optimizing material flow, these solutions lessen the burden on employees and improve workplace safety. Embracing better material handling is a foundational step toward achieving Lean Manufacturing excellence.