Lean Manufacturing System

Lean Manufacturing or Lean Six Sigma manufacturing, as it is often called, when done well, fully integrates the benefits of two technologies; Lean, which was hugely developed and expanded upon by Taiichi Ohno and his team at Toyota, whilst Six Sigma received similar efforts, mainly from Motorola. Lean focuses on waste reduction and efficiency improvement, while Six Sigma aims to reduce process variation.

At Harford Control, we embrace Lean Six Sigma as the foundation of our operations, providing a comprehensive toolkit and real-time data analysis to help businesses achieve performance optimisation.

Principles of Lean Manufacturing

Lean Manufacturing minimises wastage and improves efficiency through the principles developed by Taiichi Ohno and his team at Toyota. Lean is largely about minimising waste and improving efficiency. Six Sigma, on the other hand, is about reducing variation in the process on the premise that wherever excessive variation exists in a process, excessive loss is inevitable, a loss for which either the manufacturer or the purchaser pays.

Combining these two complementary technologies into Lean Six Sigma, whilst not invented by Harford Control, underpins the bedrock of everything we do, and gives you the best opportunity to work consistently towards performance optimisation throughout your production process.

Benefits of Lean Manufacturing

Lean Manufacturing offers numerous benefits, including waste reduction, improved efficiency, enhanced product quality, and increased customer satisfaction. By optimising raw material usage, labour utilisation and energy consumption, organisations can achieve higher productivity, reduced transformation costs, and better overall performance. Lean tools such as statistical process control, process capability, and rapid product changeovers enable continuous improvement and operational excellence.

Harford's Lean Manufacturing System

Harford Control offers a comprehensive Lean Manufacturing system that incorporates various tools and methodologies. Our system includes statistical process control, OEE (Overall Equipment Effectiveness), SMED (Single-Minute Exchange of Die), fishbone diagrams, 5Ys and more. We provide real-time data analysis and instant distribution of information to empower personnel to make informed decisions and drive performance optimisation.

All these tools and many more form part of the Harford Lean Manufacturing system, together with minimisation of operator intervention and instantly displayed, real-time analysis, prioritisation and distribution of information directly to the desktops, computer tablets or mobile phones of those personnel who have the best opportunity to take both necessary and desired improvement actions towards overall performance optimisation.

Industry Applications

Lean Manufacturing is applicable across various industries, including but not limited to dairy, spirit bottling, fresh fish packing, and ready meals. Though every business is totally different, in its type of product, portfolio of variables, production lines and its end users, each manufacturer, amongst all this complexity, is really concerned with only two things; optimisation of raw materials usage and labour utilisation. Harford Control’s Lean Manufacturing system provides the tools and support needed to address these objectives and achieve operational excellence in diverse manufacturing environments.

Harford's Lean Six Sigma Black Belt Accreditation

To ensure that Harford brings the highest level of support to the application of its integrated toolkit, all our sales professionals are accredited to Lean Six Sigma Black Belt standard. This demonstrates our commitment to delivering the highest level of support and expertise in applying our integrated toolkit.

With our accredited team, we provide comprehensive guidance and assistance to help businesses successfully implement Lean Manufacturing practices and drive continuous improvement.


  • What is Lean Manufacturing?

    Lean Manufacturing is a systematic approach that aims to minimize waste, improve efficiency, and optimize processes in manufacturing. It focuses on identifying and eliminating non-value-added activities, streamlining workflows, and fostering a culture of continuous improvement.

  • What are the key principles of Lean Manufacturing?

    The key principles of Lean Manufacturing include waste reduction, continuous improvement, value stream mapping, standardized work, visual management, just-in-time production, and respect for people.

  • What are the benefits of implementing Lean Manufacturing?

    Implementing Lean Manufacturing offers several benefits, such as increased productivity, reduced costs, improved product quality, shorter lead times, enhanced customer satisfaction, better employee engagement, and increased competitiveness in the market.

  • How does Lean Manufacturing foster continuous improvement?

    Lean Manufacturing promotes a culture of continuous improvement by encouraging employees at all levels to identify and eliminate waste, suggest process improvements, and participate in problem-solving activities. It focuses on incremental changes to drive ongoing progress and innovation. 

  • How does Lean Manufacturing improve operational efficiency?

    Lean Manufacturing improves operational efficiency by streamlining processes, eliminating waste, optimizing workflows, and reducing non-value-added activities. It helps organizations achieve higher productivity, lower costs, improved cycle times, and smoother operations. 

  • How does Lean Manufacturing help in waste reduction?

    Lean Manufacturing identifies and eliminates various types of waste, including overproduction, excess inventory, defects, waiting time, transportation, overprocessing, and motion. By reducing waste, companies can optimize resource utilization, improve efficiency, and increase profitability.