The concept of lean manufacturing, or lean as it is sometimes called, has been around for decades and focuses on streamlining production to improve value and productivity while minimizing waste. From a lean perspective, waste is considered anything that does not add value. During the lean process, companies are encouraged to map out the flow of product through the entire supply chain in an effort to identify efficiency opportunities and ensure parts flow smoothly through each phase of manufacturing.

There are many options to choose from when it comes to precision machining companies. When looking for a precision machining partner, it is important that OEMs look for a shop that delivers high-quality parts on schedule and offers value. One of the most common ways a precision machining shop, like Boston Centerless, is able to incorporate the efficiencies necessary to deliver high-quality and value is through the application of lean manufacturing principles.

As a recognized leader in lean manufacturing, Boston Centerless maintains a continuous improvement culture throughout our organization. From receipt of material to manufacturing, packaging and shipping, through purchasing and customer service, every effort is made to assure perfect quality, on-time delivery and 100% compliance to customer specifications. Visit our website to learn more about our lean manufacturing expertise.

What are the Key Strategies of Lean Manufacturing?

Below is a summary of the 5 key principles of lean manufacturing. When implemented effectively, lean manufacturing results in significant efficiencies and productivity gains that lower production costs – providing the competitive edge companies are seeking. These concepts can be successfully applied to any sector including precision machining.

1. Value – this principle is based on how the customer defines “value”. It is nearly impossible to streamline a manufacturing process if the value points are not clearly understood.

2. Value Stream – this step involves mapping out the processes that contribute to the value stream from beginning to end. It often starts with raw material acquisition and ends when the final product is delivered to the customer. This is a crucial aspect of lean manufacturing as the purpose is to identify potential waste areas and then work to reduce or eliminate the waste.

3. Flow – once the waste is removed, the manufacturing operations should run more smoothly and efficiently. Teams should revisit the value stream to ensure all waste has been removed where possible. 

4. Pull – with the process running more smoothly, products can be manufactured and delivered “just in time”, reducing inventory requirements and costs. This also results in shorter time to market, further driving competitiveness.

5. Perfection – the final principle is about continuous improvement as lean manufacturing is intended to be an on-going assessment to avoid waste and inefficiencies from creeping back into the process. Companies with a lean culture ensure all personnel are empowered to participate in continuous improvement efforts.

Types of Waste Common in Precision Machining

There are several types of waste that are often identified when a lean approach is used in precision machining, and below are some of the most common.

• Waiting: this applies to personnel or machinery. When time is wasted by waiting on machines to be available or materials to arrive, the efficiency of the machine shop suffers.
• Unoptimized Inventory: too much or too little inventory both lead to inefficiencies.
• Inefficient Logistics: logistics include the workflow of the part within the shop but also extends beyond the machine shop to include the acquisition of raw materials as well as the transportation of the final product to the customer.
• Over-processing or Over-Engineering: these are a waste of time, equipment and resources. The objective of precision machining is to meet the tolerances and specifications per the agreed upon design.
• Unnecessary Motion: this can be wasted motion of personnel or equipment. Reducing unnecessary motion is key to improving the entire manufacturing supply chain. Machine shops that are organized and laid out well excel in this area.
• Defects or Other Quality Issues: scrapped pieces and rework of off-spec parts can be a huge area of waste for machine shops if quality control is not properly built into the manufacturing process.

Would your team benefit from a precision machining partner that has a lean manufacturing approach to production?

Contact Boston Centerless to learn more about lean manufacturing expertise and how we apply lean principles to our processes.

How is Lean Manufacturing Applied to Precision Machining?

When lean principles are applied, sources of waste are reduced, or even eliminated, improving operations efficiency and product quality - adding significant value for customers. With shorter production times, shops are more nimble and able to respond to customer needs and market conditions. Below are examples of how lean principles can be applied to precision machining projects.

• Establish a Lean Shop Culture: each precision machining shop has its own culture that permeates every aspect of the shop including the manufacturing process. It is important that all levels of the organization participate in the lean culture from management to the shop floor. It is important to explain to personnel why a lean approach and efficient manufacturing is critical to business success. Personnel need to know that if they identify an improvement opportunity their ideas will be heard and considered. At Boston Centerless, a key focus of our lean manufacturing techniques is maximizing customer value while minimizing waste - and we empower every employee to make a difference.
• Organize the Shop Floor for Success: the physical layout of a machine shop and the workflow path a part takes directly impact productivity, namely the level of unnecessary motion. Machine shops that want to apply lean manufacturing principles should follow raw materials throughout the manufacturing process to better understand areas for improvement. For example, are raw materials near the CNC equipment, and is finishing machinery located near the shipping and transport area of the shop. Simple measures like the location of equipment as well as the placement and order of CNC machining tools can have a huge impact on manufacturing efficiency.
• Tool Selection and Utilization: tooling efficiency is essential as it can make or break the quality of parts produced by precision machining. Selecting the right tools is key to achieving a high-quality cut, effectively minimizing the potential for defects. It is also important that operators carefully plan their operating conditions such as feed rate and speed to achieve the most value from a given machine.
• Optimized Maintenance Plan: precision machining shops are becoming increasingly aware of the downtimes and costs resulting from unexpected equipment failures, and are implementing a combination of preventative and predictive maintenance plans to secure a competitive edge.  Maintenance programs that rely solely on manual data entry and tracking are slow and are often too “reactive” in nature – it is key to integrate smart, condition-based monitoring systems into existing precision machining processes. These smart programs provide manufacturers with scheduled maintenance events based on known wear, use or observed conditions as well as dashboard monitoring and trends. The bottom line is to be proactive rather than reactive to better achieve lean manufacturing.

About Boston Centerless

Boston Centerless provides solutions that enhance our customer’s manufacturing processes. With over 60 years of experience with precision machining, we grind the tightest tolerances in the industry. When we were established, we were primarily a centerless grinding company, and over time we expanded our offerings to include manufacturing and distribution of precision raw materials and material preparation services.

We are a fully integrated product and service provider that can assist you with material selection, procurement, grinding, material testing and validation, customized inventory programs and supply chain management. Since we can procure and grind your material, we serve as your “one-stop shop” – saving time and money, and reducing risk, across your supply chain. We have proven experience with an extensive range of materials, and our manufacturing solutions include:

• AccuRod® Precision Bar
• BC Medical Grade
• Grinding Services
• Ultra-Precise Gages
• Value-Added Services
• Material Testing & Validation
• Supply Chain Management
• SwissAssist

Contact us today at (781) 994-5000 to see how we can help with your next precision machining project, or click here for a quote.