IB Design Technology 10.2 Lean Production Notes

Lean Production: Principles, Practices, and Challenges

1. Imagine you’re managing a car production line.
2. Every minute, materials pile up, workers wait for instructions, and finished cars sit in storage, waiting to be shipped.
3. You’re losing time, money, and efficiency.
4. How can you streamline this process to maximize productivity and minimize waste?
5. This is where lean production comes in.

Core Characteristics of Lean Production

At its heart, lean production is about creating value with fewer resources.

1. Waste Reduction

1. Lean production identifies and eliminates waste—activities that consume resources without adding value to the final product.
2. Waste can take many forms, which we’ll explore later, but the goal is always to streamline processes and focus on what truly matters to customers.

2. Resource Optimization

1. Emphasizes efficiency in the use of materials, labor, and energy.
2. By carefully managing resources, companies can reduce costs and improve sustainability.

3. Continuous Improvement

1. Lean production is not a one-time fix—it’s a mindset of ongoing refinement.
2. Known as Kaizen, this principle encourages teams to make small, incremental improvements in every aspect of the production process.

Principles of Lean Production

1. How does lean production achieve its goals?
2. It relies on several key principles, including value stream mapping, workforce empowerment, and the 5 S’s framework.

1. Value Stream Mapping

1. Imagine a map that shows every step in your production process, from raw materials to finished goods.
2. Value stream mapping helps visualize workflows, identify bottlenecks, and eliminate inefficiencies.