Lean production considers product and process design as an ongoing activity and not a one-off task, and should be viewed as a long-term strategy.

• Characteristics of lean production

• Principles of lean production

• Value stream mapping

• Workflow analysis

• Product family

• Role of the workforce

• Kaizen

• Lead time

• The 5 Ss: sorting, stabilizing, shining, standardizing, sustaining the practice

• The 7 wastes: overproduction, waiting, transporting, inappropriate processing, unnecessary inventory, unnecessary/excess motion, defects

• Characteristics of lean production include JIT supplies; highly trained multi-skilled workforce; quality control and continuous improvement; zero defects, zero inventory

• Principles of lean production include: eliminating waste; minimizing inventory; maximizing flow; pulling production from customer demand; meeting customer requirements; doing it right the first time; empowering workers; designing for rapid changeover; partnering with suppliers; creating a culture of continuous improvement (kaizen)

• The role of the workforce includes training, devolution in power relating to process improvement and kaizen

• Consider the contribution of value stream mapping and workflow analysis to the design of an effective lean production method

• Advantages and disadvantages of lean production

The role of the workforce in lean production is paramount, relying on their wisdom and experience to improve the process, reducing waste, cost and production time. Recognizing this results in motivated workforces whose interests are in the success of the product.