skip to content
 info@wolfrayet.com
Call: 940 336 1120
wolfrayet logo

Lean Manufacturing and Powder Coating

If you have ever considered introducing Lean Manufacturing, or would like to learn more about it, or have no idea what it is. 
Read on! 
lean manufacturing 01

What is Lean Manufacturing?

Lean manufacturing is a production philosophy that aims to maximize efficiency and eliminate waste in manufacturing processes. It focusses on identifying processes that add value, and making them as efficient as possible by reducing any identified 'wastes' attached to that process.
It can be applied to any manufacturing process, including powder coating.
Read on to discover how it can help your powder coating operation.

What can Lean do for my business?

If your company is involved in any form of manufacturing, there will be areas of weakness. Regardless of size, there are always improvements that can be made. These improvements will positively impact 'bottom line' success.
Often, managers can be reluctant to make changes in one area as it impacts another. Before you know it the whole task becomes overwhelming.
Fortunately Lean Manufacturing offers solutions that easily identify the place to start, what to do now, and what to do next.
lean manufacturing 03
lean manufacturing where to start

Where to start

Firstly, spend some time to identify the areas in your business that you think could be improved. Your results will probably fall under one or more of the following headings:
  • Increased Efficeincy
  • Cost Reduction
  • Improved Quality
  • Lead Times
  • Flexibility (people and resources)
  • Employee Engagement
  • Customer Satisfaction

Make a note of the top 3. Before the solutions can be found, we need to understand the concepts of 'The Value Stream' and 'The Seven Wastes'

The Value Stream

If you have made an accurate assessment of  the weaknesses in your powder coating operation, knowing where to start can be a problem. Firstly you need to look at 'The Value Stream'.

'The Value Stream' is the complete process from raw materials to finished products that creates value for the customer. It includes all the steps, resources, and information needed to create the end product.

Consider part of the flow of processes in a powder coating facility:

  1. The part is in a bin awaiting cleaning (no value being added)
  2. The part is in a cleaning tank (value is being added)
  3. The part is in a bin awaiting primer application (no value being added)
  4. The part is in the spray booth and primer powder is being applied (value is being added)

Now, identify and 'walk' your 'Value Stream'. Look at every process in detail and find and eliminate the wastes! There is a 'Toolbox' of different waste eliminating procedures that can be carried out which you can find here.

The time spent where value is not being added is 'Waste'. The aim in Lean is to identify the 'Waste' and reduce it. It is not huge step to now work out that in this case, reducing the waste, improves the lead time and increases production capacity.

Read the following section on 'The Seven Wastes', and work out which of the seven is the 'Waste' in the above example.

While these parts are stacked up on a pallet, no value is being added. 
Lean powder coating
Powder is being applied to these parts, so value is being added.

Understanding the concept of 'The Seven Wastes'

Simply put, Lean Manufacturing is a philosophy focused on achieving efficiency by waste elimination.
If you consider the top three areas that you identified previously, that need improvement, there will be 'wastes' attached to those areas that could be eliminated or reduced.

What is Waste?

Waste in manufacturing processes can be split into:

  • Overproduction

    • Producing more than what is needed or producing ahead of demand. This leads to excess inventory, increased costs, and wasted resources.

  • Waiting

    • Delays or idle time in any production process. This can be waiting for materials, equipment, or instructions. Waiting wastes time, slows down production, and reduces overall efficiency.

  • Transportation

    • Unnecessary movement or transportation of materials or products within the manufacturing process. Excessive transportation increases lead times, adds to costs, and poses a risk of damage or loss.

  • Inventory

    • Excess inventory beyond what is necessary for immediate production or customer demand. Inventory ties up capital, requires additional storage space. There is also an increased risk of obsolescence or damage.

  • Motion

    • Unnecessary or excessive motion by workers due to:
    • Poorly designed workstations
    • Inadequate tools
    • Inefficient processes
    • Excessive motion can lead to fatigue, errors, and reduced productivity

  • Overprocessing

    • Performing more work or using more resources than required to meet customer requirements or specifications. Overprocessing adds unnecessary cost and time without adding value.

  • Defects

    • Defective products, rework, or quality issues that result in scrap, repairs, or customer dissatisfaction. Defects lead to wasted materials, additional work, and can harm the company's reputation.
 

Ready to find out more?

Start the conversation
WolfRayet
Powered by  GDPR Cookie Compliance
Privacy Overview

This website uses cookies so that we can provide you with the best user experience possible. Cookie information is stored in your browser and performs functions such as recognising you when you return to our website and helping our team to understand which sections of the website you find most interesting and useful.