In the late 1990s, an American company made changes to its processes that halved the final assembly time for one of its flagship products. That company was Boeing, and the changes applied to the 737 model, now one of the most popular passenger planes in the skies. The key to this success was lean manufacturing—a Japanese production system born in Toyota’s factories.
Today, Felgenhauer successfully employs the same principles, focusing solely on what truly matters to customers and employees
“Predictability, organization, and a relentless pursuit of better solutions. It may not sound thrilling, but it ensures safety, eliminates errors, and boosts quality. At Felgenhauer, we’ve been applying lean manufacturing principles for years. This system aligns with our goals and delivers measurable benefits for the company, employees, and clients,” explains Piotr Sienkiewicz, Felgenhauer’s Sales Director.
What Is Lean Manufacturing?
Lean manufacturing is a method of managing production processes based on continuous improvement. The goal is to eliminate waste, enhance efficiency, and improve quality. The system relies on employee engagement and removing anything unnecessary—such as downtime, overproduction, and excessive inventory.
“Every action must be efficient, effective, and beneficial for the customer. The result? We deliver exactly the product the customer expects, on time,” adds Sienkiewicz.
One of the people responsible for creating this concept is Taiichi Ohno. He developed and applied lean production techniques within Toyota’s processes, which is why they are often referred to as the Toyota Production System (TPS). The key principles have been illustrated graphically through the ‘Toyota House.’
But can a system originating in Japan work in Polish industry?
The Japanese Philosophy at Felgenhauer
The principles developed by Toyota have proven so universal that they’ve been successfully adopted by companies worldwide—not only in Asia. Even decades later, they remain as relevant as when first introduced.
The system has been implemented at Felgenhauer for years, yielding tangible benefits such as:
- Increased productivity
- Elimination of downtime
- Maintenance of product quality
- Reduction of production waste
- Improved communication within the company
- Greater employee engagement
Key Elements of Lean Manufacturing at Felgenhauer
KAIZEN – Continuous Improvement
If something can be done better, we do it. Continuous pursuit of excellence is key to our company’s growth. We actively involve employees in this process, as they are the first to notice potential issues and propose solutions to enhance their work.
SMED – Minimizing Tool Changeover Time
Standardizing actions and programming machines efficiently speeds up every process. During changeovers, we ensure quality to avoid errors.
5S – Sort, Set in Order, Shine, Standardize, Sustain
Well-designed and organized workstations are essential for smoother operations and improved safety. We maintain a vigilant focus on cleanliness and order in our work environment.
FMEA – Problem Prediction
Before starting any project, we identify weak points. We analyze potential issues at every stage of production and develop preventive measures. Clients can order prototypes or sample products before serial production begins, ensuring readiness for unforeseen challenges.
GEMBA – Staying Close to Production
Decision-makers are present on the production floor, familiarizing themselves with every department and its workers. By observing processes firsthand, rather than relying solely on reports, they can better understand issues and identify areas for improvement.
Lean Manufacturing Benefits for Employees
“Where do you see yourself in 10 years?” It’s a common interview question, but how can anyone answer confidently if the future of the company is uncertain?
A proven system like lean manufacturing ensures that a company thrives not only during prosperous times but also in challenging economic conditions. For employees, this means stability and job security.
But stability is not the only benefit of lean manufacturing:
| Empowerment | Employees actively participate in the improvement process, influencing how their work is done. |
| Skill Development | People are our greatest asset, so we invest in training and support their professional growth. |
| Safety | Eliminating errors, predicting breakdowns, and maintaining well-organized workspaces enhance employee comfort and safety. |
| Less Stress | When everything is planned and organized, work flows more smoothly. This fosters a calmer atmosphere, making it easier to maintain a healthy work-life balance. |
| Satisfaction | Knowing that success is a team effort is invaluable. |
“Quality is never an accident. It is always the result of intelligent effort,” said English thinker John Ruskin. Today, the focus is increasingly on working smarter. At a company employing over 1,000 people and producing tens of thousands of products each month, this wouldn’t be possible without an effective process management system. That system is the foundation of Felgenhauer’s success—ensuring product quality, employee safety, and a prosperous future for all involved.
