The term lean production was introduced in the 1990s with the Toyota Production System and has been continuously developed. Lean Production helps companies to use their production factors efficiently. Companies in different industries have developed and implemented their own production systems. ifp consulting supports its clients in creating an individual concept for their product based on basic principles, system elements and methods that pursue clear goals and performance indicators.
The basic principles include customer-oriented value creation, efficient value streams, continuous flow principle and continuous improvement. The system elements are based on methods for optimizing the processes, organization and behavior of people. This optimization streamlines workflows and processes, resulting in positive effects such as higher productivity, better quality and lower costs. Lean production thrives on positive real-world experience. Therefore, it is recommended to carry out the transformation process in the form of a pilot application. It is extremely important that executives and management exemplify the principles and act as coaches for employees, because a successful production system depends on the participation of everyone.
When implementing a production system, digital solutions for direct and indirect production areas can also be integrated. This concerns direct production areas (manufacturing, assembly, testing) as well as indirect areas (logistics, quality, maintenance, IT system) and support functions (HR, finance, controlling, purchasing).
Examples of such approaches include preventive and predictive maintenance routines and digital performance management. Digital dashboards (Andon boards) make key performance indicators visible to employees and management in real time. Deviations can be quickly detected and corrected, which avoids errors and saves costs. Additional incentive systems motivate employees and support the continuous improvement process (Kaizen).