Lean manufacturing in its essence is “a business proposition to reduce waste in manufactured goods. The fundamental idea is to scientifically reduce costs, during product development and manufacturing, through a series of company reviews.” It's about making incremental improvements to the production process, involving all parties involved, in order to become more efficient by reducing waste. Say no to plagiarism. Get a tailor-made essay on "Why Violent Video Games Shouldn't Be Banned"? Get an Original Essay Waste Minimization Waste reduction is an important part of lean manufacturing and Taiichi Ohno, who was a Toyota engineer who came up with the Toyota Production System (TPS) ) we classified 7 types of waste: Overproduction Waiting Unnecessary movement Transport Processing Inventory Defects. In our setup, waste minimization is critical to our success. Production will be carried out according to orders without having a large inventory. This will also take into account changing fashion and trends. Proper material planning and forecasting will be conducted to avoid bottlenecks along the line. In line with "unnecessary movements", we will strive to create the most ergonomic workflow on the line for the benefit of shop floor employees. Work process People involvement All employees will be encouraged to speak openly and propose ideas on how to make the production line more efficient and to report any problems. Since there are many production stations along the line, each one can be made more efficient and who better to know this than the people who work there. Continuous Improvement Continuous improvement is one of the fundamental aspects of Kaizen, a Japanese management method focused on continuous improvement at all times. In essence, Kaizen is: “an approach in which all people working in a production site consider measures to improve quality and productivity by doing everything possible to reduce waste in the production process and implementing these measures in their work”. From this definition we can clearly see that Lean Manufacturing and Kaizen are closely related. We will obviously implement Kaizen in our factory and will strive to collaboratively continue to improve every part of the production line, as well as all the administrative procedures that feed it. Pull Systems A pull system in manufacturing refers to the production process that is triggered by demand. That is, inventory is kept to a minimum and stocks are kept minimal. Once an order is received, the entire production line goes into motion to fulfill it. This also falls within the scope of Lean Manufacturing or Kaizen, and allows for minimal waste while being able to produce quickly and efficiently based on actual orders. The main difference between pull systems and push systems is that a pull system is based on “Make to Order” while a push system is based on “Make to Stock”. We will use a pull system where production will be made to order, with minimal stock and inventory. Setup reduction Setup reduction refers to the time required to set up production machines to make a specific batch. In line with the above, most of our machines will be configured specifically for each batch (order), which will need to be taken into account when planning. However, the only stations that require a particular setup are those machines that die-cut the different pieces that make up the.