Mass production—popularized by Henry Ford and Ford Motor company in the 1920s—focuses on maximum output for maximum profits based on forecasts of demand, but this can lead to overproduction, quality issues, and waste.
Lean manufacturing, however, is a strategy that prioritizes waste reduction and promotes system-wide efficiency. Lean principles rely on highly-skilled teams, production flexibility, and customer demand—adjusting for overall efficiency as opposed to settling for individual productivity. Lean manufacturing is a sustainable, competitive advantage that delivers high-quality, low-cost product. In short, lean manufacturing is a commitment to continuous improvement and team collaboration to deliver the best possible products.
Lean Principles
DMAIC: Design, Measure, Analyze, Improve, Control
The core principle for our quality program.
VOC: Voice of the Customer
The first step in determining how we can add value.
VSM: Value Stream Mapping
Allows us to determine how we can improve processes.
5S: Sort, Set in Order, Shine, Standardize, Sustain
Method of maintaining organization.
Seven Waste
Eliminating waste in inventory, waiting, defects, overproduction, motion, over-processing, transportation.
Each of the processes were set in place to assess risk vs. cost. In manufacturing, the risk is potential poor quality or low efficiency and the cost is the total to produce the product with and without automation. Our goal is always to provide the customer with a top-level quality product while still maintaining the best value in the market. These lean principles are key in finding that balance for our customers.
TCCI uses a hybrid of automation and labor practices which helps eliminate waste and increase efficiency across our facilities. We strive for continuous improvement in every facet of the business—customer communications, best practices, lessons learned and advancing technology guide our decision-making for all processes. A well-established, cross-functional approach ensures information is shared across departments and locations for efficacy and consistency. By understanding our customer’s needs, goals and expectations, we can design and deliver better products.
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