WHAT IS LEAN PRODUCTION ?

Lean production is a “Company Strategy” that increases productivity by continuously reducing waste in the system, shortens the “lead times” of the processes of all departments of the company, improves the “quality, cost and delivery” factors of the products demanded by the customer, thereby increasing the profitability and competitiveness of the company.

Progim ensures that lean manufacturing techniques are practically implemented in the field. Thus, the perspectives of all employees towards the new system transform positive in a short time.

Employees see that theory of the system is very powerful in trainings and realize that their practices are easily applicable in the factory. We realize “Lean Transformation” with weekly “Kaizen Workshops” with our consultants having many years of field experience.

Since the establishment of Progim, we have implemented lean manufacturing practices with hundreds of successful kaizen workshops.

Kaizen workshops are improvement team works in the selected region within a week. We apply this method so successfully and effectively that SMEs can visualize at the end of first week what kind of a company they will become 6 months-1 year later. This ensures the trust of all employees of the company to the "Lean Production System" from the first week.

Our aim is not to fish in businesses, but to teach how to fish.

Factory employees actively participate in workshops and learn this system, and over time, they can perform kaizen workshops on their own.

Thus, the lean manufacturing system is maintained by the company resources.

Savings by Lean Transformation

In addition to the financial savings given above, lean transformation also has very important additional non-financial benefits. Your employees will also achieve the following important gains:

Gains To Employees

Muda – Mura – Muri three terms (called 3M) that are often used together in the Toyota Production System to collectively describe wasteful practices that need to be eliminated .

Lean Production: The Way to Increase Efficiency and Reduce Waste

In today’s competitive business world, increasing productivity and minimizing waste has become a priority for every business. One of the most effective ways to achieve these goals is to apply lean production techniques to establish a lean production system. So, what is lean production and how does it benefit businesses?
In this article, we will discuss the key details about lean production.

Lean Production Techniques

Lean production is a management philosophy that aims to increase efficiency by reducing waste in the production process. Lean production techniques include various methods such as value stream mapping, the 5S method, continuous improvement (Kaizen), SMED, TPM, and pull systems (Kanban). Thanks to these techniques, businesses can make their production processes more effective and reduce costs.

Lean Production System

Lean production system enables businesses to create a sustainable and efficient production process by applying lean production techniques. These systems enhance the ability to respond quickly to customer demands and help prevent production errors. Thanks to the lean production system, businesses can both optimize their internal processes and increase customer satisfaction.

Lean Production Training

To successfully implement lean production, it is important to train employees on this subject. Lean production training teaches employees the philosophy, techniques, and application methods of lean production. These training programs help employees manage production processes more efficiently and adopt a culture of continuous improvement.

Lean Production Consulting

For businesses embarking on the journey of lean production, lean production consulting provides significant support. Lean production consultants develop customized strategies for companies and help them implement lean production techniques in the most effective way. Consulting services cover areas such as the implementation of lean production systems, providing training, and managing continuous improvement processes.

Lean Production Thanks to this, businesses can both reduce their costs and increase their efficiency. By adopting this management philosophy, they can gain a competitive advantage and achieve sustainable success.

LMAA - Lean Maturity Assessment Analysis

For industrial enterprises, achieving the goals of efficiency, sustainability, and competitiveness depends on lean transformation. At the same time, reaching a certain level of maturity in lean production is also critical for a successful digital transformation process.
In order for businesses to take the right steps in their lean and digital transformation journeys, they must first clearly understand their current situation and have a solid roadmap.

As Progim Lean Transformation and Software, we implement the Lean Maturity Assessment Analysis (LMAA) for industrial enterprises of all sizes and sectors. Based on this analysis, we prepare a detailed, company-specific Lean Maturity Assessment Report, laying the foundation for the lean transformation journey.

LMAA evaluates all processes of the enterprise — from production to management, from information flow to resource utilization — in line with lean production principles; it reveals the current situation and identifies improvement potentials.

For this analysis, Progim’s senior consultant visits your company on-site for a full day. They examine the production area, observe practices, and conduct face-to-face interviews with relevant teams while applying the LMAA questions. Afterwards, through an intensive evaluation process, the Lean Maturity Assessment Report is prepared and delivered to the company.

The methodology we apply is based on the official LMAA systematics developed by KOSGEB. Progim consultants are authorized and certified experts in this field by KOSGEB.

This analysis is not only necessary to benefit from KOSGEB supports, but also to clearly see the company’s level of leanness and establish a solid foundation for digitalization and sustainability investments. LMAA provides an effective roadmap that simplifies and standardizes the company’s core processes while reducing waste.

How is the LMAA Process Implemented?

Assessment Dimensions: LMAA covers six key critical dimensions that form the foundation of lean production principles.

Top management involvement,
Value stream analysis,
Standardization,
Pull Systems,
Continuous flow,
Continuous improvement (Kaizen)

includes topics such as.

KOSGEP Support Rates

KOSGEB offers various support programs to help businesses adopt and develop lean production processes. In this context, the Lean Maturity Assessment Analysis (LMAA) Service Support helps businesses analyze their current situation and identify areas for improvement.

Lean Maturity Assessment Analysis (LMAA) Service Support:

Support Rate: %80
Support Upper Limit: 40,000 TL (20,000 TL for each LMAA)
Support Scope: Analysis services required by businesses in their lean transformation processes

LMAA ! It should be noted that businesses without a lean transformation process may not achieve the expected benefits of digital transformation. Therefore, Lean Maturity Assessment Analysis is a strategic step for any business that wants to plan its future correctly.

Lean Production and Digital Transformation

Today, digital transformation helps businesses apply “lean production” techniques more effectively. Through real-time monitoring and analysis of data, “digital transformation” makes it much easier to identify and improve problems in production. For example, “IoT (Internet of Things)” devices and artificial intelligence algorithms quickly detect bottlenecks and waste on the production line, helping to increase efficiency.

Lean Production and Sustainability

Lean production not only increases efficiency but also plays an important role in achieving sustainability goals. Lean production techniques ensure more efficient use of resources and minimize waste. This contributes both to reducing environmental impacts and to helping businesses achieve their long-term sustainability objectives.

Lean Production and Employee Participation

Lean production encourages employee involvement and collaboration. Techniques such as Kaizen and 5S enable employees to actively participate in continuous improvement processes. This participation increases employee motivation and strengthens collaboration within the company. In addition, when employees make improvements in their own work processes, overall productivity increases.

Lean Production and Customer Satisfaction

Lean production is the key to increasing customer satisfaction. Thanks to lean production techniques, businesses can respond to customer demands more quickly and flexibly. Minimizing errors in production processes contributes to higher product quality and, consequently, greater customer satisfaction.

Lean Production and Competitive Advantage

Lean production provides businesses with a significant competitive advantage. Increased efficiency and reduced costs allow companies to offer more competitive prices in the market. In addition, flexibility and speed in production processes help them quickly adapt to changing market conditions.

Lean Production Businesses that adopt this philosophy both optimize their internal processes and gain a competitive advantage in the market. In this way, long-term success and sustainable growth can be achieved.

What Are the 5 Principles of Lean Production?

“Lean production” is a management philosophy inspired by the Toyota Production System and adopted worldwide. Lean production has five fundamental principles: Value, Value Stream, Flow, Pull, and Perfection. These principles help businesses optimize their production processes and minimize waste. Here are the five principles of lean production:

1. Value

The first principle of lean production is ‘value’. It refers to a product or service with specific features created by the producer in line with customer needs. Businesses must understand what customers truly need and what they are willing to pay for. Correctly defining value helps companies eliminate unnecessary activities and waste. By adopting the customer’s perspective, production processes focus on these values, thereby increasing customer satisfaction.

2. Value Stream

The second principle, value stream, includes all the steps a product or service goes through from raw material to the end user. Each of these steps is evaluated as activities that either add value or do not add value to the customer. The value stream mapping method enables the identification and elimination of waste. In this process, unnecessary steps and activities are removed, and the value stream is optimized. As a result, the production process becomes more efficient and costs are reduced.

3. Flow

The flow principle refers to the uninterrupted and continuous progression of the production process. In traditional production methods, it is common for work to accumulate at certain stages and for delays to occur. Lean production aims to eliminate these interruptions and ensure continuous flow. By minimizing bottlenecks and waiting times on the production line, products or services can reach the customer quickly and smoothly. This shortens production times and enables faster responses to customer demands.

4. Pull System

The fourth principle, the pull system, refers to producing according to customer demand. In traditional push systems, products are manufactured for stocking and then offered to customers. However, the pull system produces based on customer requirements and prevents unnecessary inventory accumulation. In this system, subsequent processes pull the necessary materials from previous processes using simple “Information Sharing/Communication” methods. Thus, whatever is needed is produced exactly when it is needed.

5. Excellence

The final principle, perfection, is the pursuit of continuous improvement and excellence. Lean production always aims to achieve better results. This principle emphasizes that businesses must constantly review their processes and make improvements. Known as Kaizen, this philosophy of continuous improvement encourages the involvement of all employees. By adopting the principle of perfection, businesses increase their efficiency, reduce costs, and gain a competitive advantage.

Lean Production The five principles help businesses increase their efficiency and minimize waste. Companies that adopt the principles of value, value stream, flow, pull, and perfection achieve sustainable success and customer satisfaction. These principles form the cornerstone of lean production and enable businesses to gain a competitive advantage.