AQA · GCSE · Business
Course version: 8132 · Version from Sept 2017
Production processes: lean production
Lean production is an approach that seeks to minimise waste in every area of operations while still meeting customer needs.
Checked against the AQA 8132 specification (opens in a new tab) on .
- Point 7 of 8
- 3 key terms
Study notes
From the checked teaching notes for this specification point.
The idea
Lean production is an approach that seeks to minimise waste in every area of operations while still meeting customer needs. Waste includes overproduction, waiting time, unnecessary transport, over-processing, excess inventory, unnecessary motion and defects. Techniques include just-in-time (JIT) stock control, where materials arrive as production needs them; kaizen, or continuous improvement by workers; and cell production, where teams complete whole units. The aim is greater efficiency: more output from each unit of input, such as labour, materials or time. For example, a furniture maker using JIT holds little timber, freeing cash and space, but must trust suppliers to deliver on time. Lean can lower costs and improve quality, yet it can also raise the risk of stockouts and may meet resistance from staff facing changed working practices.
What earns the marks
- Define lean production as minimising waste while meeting customer requirements, improving efficiency.
- Identify types of waste, such as overproduction, waiting, excess inventory, transport, motion, over-processing and defects.
- Describe lean techniques including just-in-time stock control, kaizen and cell production.
- Explain how lean production lowers costs, for example through reduced stockholding, less rework and better use of labour.
- Explain limitations, such as dependence on reliable suppliers, risk of stockouts and possible employee resistance.
Common mistakes and how to put them right
Defining lean production only as using less stock.
Put it right by stating it covers all forms of waste across operations.
Believing lean production always reduces costs immediately.
Put it right by noting implementation can require investment and time before savings appear.
Confusing kaizen with a one-off improvement project.
Put it right by describing kaizen as continuous, ongoing small improvements.
Exam tips
- Link each lean technique to a clear efficiency benefit, such as lower inventory costs or faster production flow.
- Use a real or named business example to show how lean production works in context.
- When evaluating, weigh cost savings against risks such as supply disruption before giving a judgement.
Try the lesson
The start of the Production processes: lean production lesson, made from checked teaching notes for this specification point.
Have a go first
What is meant by lean production?
Listen
Lean production is an approach that seeks to minimise waste in every area of operations while still meeting customer needs. Waste includes overproduction, waiting time, unnecessary transport, over-processing, excess inventory, unnecessary motion and defects. Techniques include just-in-time (JIT) stock control, where materials arrive as production needs them; kaizen, or continuous improvement by workers; and cell production, where teams complete whole units. The aim is greater efficiency: more output from each unit of input, such as labour, materials or time. For example, a furniture maker using JIT holds little timber, freeing cash and space, but must trust suppliers to deliver on time. Lean can lower costs and improve quality, yet it can also raise the risk of stockouts and may meet resistance from staff facing changed working practices. A strong answer earns marks for these points. Define lean production as minimising waste while meeting customer requirements, improving efficiency. Identify types of waste, such as overproduction, waiting, excess inventory, transport, motion, over-processing and defects. Describe lean techniques including just-in-time stock control, kaizen and cell production. Explain how lean production lowers costs, for example through reduced stockholding, less rework and better use of labour. A common slip: Defining lean production only as using less stock. Instead, stating it covers all forms of waste across operations. Exam tip: Link each lean technique to a clear efficiency benefit, such as lower inventory costs or faster production flow.
See it
Key words
Say what each word means before you turn the card.
Efficiency and productivity
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Just-in-time stock control
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Continuous improvement
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See every definition
- Efficiency and productivity
- Greater efficiency means more output from each unit of input, such as labour, materials or time.
- Just-in-time stock control
- Materials arrive as production needs them, so little stock is held.
- Continuous improvement
- Kaizen, or continuous improvement by workers, is a lean technique.
Label the diagram
Some boxes have lost their names. Pick the right name for each number.
1Box 1
2Box 2
3Box 3
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