Lean manufacturing principles are a set of guidelines and best practices that focus on maximizing efficiency and minimizing waste in manufacturing operations. Originating from the Toyota Production System (TPS) created in the 1950s, these principles include Value, Value Stream, Flow, Pull, and Perfection, and they can have a significant impact on the overall success of a manufacturing operation. When it comes to hiring process engineers, it’s important to consider how they align with these principles, as they can play a crucial role in driving improvements and efficiencies in the manufacturing process.

Continuous Improvement

Before we dive into the importance of lean manufacturing principles when hiring process engineers it’s worth mentioning the concept of Continuous Improvement. Also known by the Japanese word Kaizen, Continuous Improvement emphasizes that there is always room for improvement and that small, incremental changes can lead to significant gains over time. It encourages a culture of learning and development within the organization, where employees are encouraged to identify and solve problems and suggest improvements to the manufacturing process. This can lead to increased engagement and motivation among employees, which can further contribute to the efficiency and effectiveness of the manufacturing process.

Keep this concept in mind when searching for top-notch process engineers, as they will most likely embrace this way of thinking.

1. Identify Value

The lean manufacturing principle of Value involves identifying what is valuable to the customer and aligning all processes and activities around providing that value. This principle emphasizes that the customer is the most important aspect to consider, and the processes and activities should be designed and executed to meet the customer’s needs and requirements.

When hiring process engineers, it’s important to look for candidates who truly understand this principle. They should be able to conduct customer research and use their findings to design and execute processes that meet your customer’s needs and align with their expectations.

For example, a process engineer might implement a survey and find out that customers are looking for faster delivery times. The engineer can then design and implement processes that focus on reducing lead times and increasing the speed of delivery. This can include implementing automation systems, redesigning the layout of the production area, and reducing the number of steps required in the production process.

2. Map Value Stream

The principle of Value Stream involves creating a visual representation of all the steps and activities involved in creating a product or service, from raw materials to delivery to the customer. This principle emphasizes the importance of understanding the entire process and identifying areas that add value and those that do not.

Process engineers should be able to identify areas that add value and those that do not and based on the analysis be able to implement changes to eliminate waste and improve efficiency.

For example, a process engineer might find that there are a lot of delays and bottlenecks in the process of receiving and inspecting raw materials. By analyzing the value stream map, the engineer can identify the cause of these delays and implement changes such as introducing new technologies or implementing new workflows to eliminate these bottlenecks.

3. Create Flow

The principle of Flow refers to the smooth and efficient movement of materials and information throughout the entire production process. In lean manufacturing, the goal is to create a steady flow of materials and information, with minimal delays or disruptions.

Process engineers need to be able to design systems that minimize delays and disruptions in the production process like implementing a “Just-In-Time” (JIT) inventory system. In JIT, raw materials and components are delivered to the production line only as they are needed, instead of being stockpiled in advance. This reduces the amount of inventory that needs to be stored and handled, which can lead to fewer delays and disruptions in the production process. It also reduces the amount of money tied up in inventory and the risk of materials becoming obsolete.

4. Establish Pull

The Pull principle refers to the idea that production should be driven by actual customer demand, rather than by forecasts or schedules. In a Pull system, the production process is triggered only when a customer orders a product. This approach helps to minimize waste by only producing what is actually needed, rather than producing large amounts of inventory in advance.

When it comes to hiring process engineers, it’s important to look for candidates who can design systems that are flexible and responsive. This can include implementing systems that can easily adjust production levels in response to changes in customer demand.

A Kanban system would be a great example of a flexible design that a process engineer might implement. Kanban is a visual method of signaling the need for the replenishment of materials. It is used to control the flow of materials and production, allowing for a flexible and responsive production process. When a customer orders a product, a signal is sent to production to build that product. This allows production to match the rate of customer demand and minimize the waste of producing excess inventory.

5. Pursue Perfection

Last, but certainly not least, is the principle of Perfection. Also known as “aim for perfection” or “zero defects”, Perfection emphasizes the importance of achieving the highest possible levels of quality and efficiency in the manufacturing process. This principle encourages organizations to continuously strive for perfection and to identify and eliminate any defects or variations in the production process that can lead to poor-quality products or inefficiencies.

The best process engineers are committed to achieving the highest possible levels of quality and efficiency in the manufacturing process. This can include implementing rigorous quality control systems, training employees on best practices, and using advanced technologies to improve production.

A process engineer striving for the highest possible levels of quality and efficiency might implement a Total Quality Management (TQM) system. TQM is a management approach that seeks to optimize the quality of the product and the efficiency of the production process by involving all employees in the quality control process. In TQM, process engineers work closely with employees to identify and eliminate defects and variations in the production process and to implement best practices and advanced technologies to improve production. This leads to an increase in the quality of the product and an increase in the efficiency of the production process, ultimately aiming for perfection.

Conclusion

Lean manufacturing principles are critical guidelines that can have a significant impact on the overall success of a manufacturing operation. When hiring process engineers, it’s important to look for candidates who understand and are committed to these principles as they can play a crucial role in driving improvements and efficiencies in the manufacturing process.