Lean Manufacturing Tools

Posted on By engineeringwithmanagement@gmail.com 33 Comments on Lean Manufacturing Tools

Lean manufacturing is a basically approach to optimize the processes with the help of different lean manufacturing tools. The usage of each tool identify system or process abnormalities and doing some valuable improvement in processes. In this article we discuss overview of lean manufacturing tools. Now a day’s each and every organization is focused to improve process and minimize the cost with maintaining customer satisfaction. Now, each and every sector as well as each and every industries competitive environment play a vital role.

Lean Manufacturing Tools

Work place & Visual management

• 6 ‘S’ Implementation

6 ‘S’ is a very basic and fundamental tool of lean manufacturing. 6 ‘S’ is a developed workplace in an organize way to increase efficiency and minimize process waste. It divided into 6 stages as per mention below.

  • Sorting
  • Set-in-order
  • Shine
  • Standardize
  • Sustain
  • Safety

• Andon

Andon is a basically signal that helps to identify abnormal or out of control activities during process performance. Generally, it’s a visual or alarming signal for abnormalities of machines or processes.

• Visual management

Visual management is a visual communication tools. Generally, for visual management display some operational data into LED screen at workplace and developed healthy competitive environment. 6 ‘S’ and Andon signal helpful to make visual workplace.

• GEMBA

The meaning of GEMBA is “the real place”. The main objective of GEMBA tool is analyze and improve process at shop floor or where process is performed. Rather than taking improvement decision in office, go to shop floor understand practical problem and improve process.

Opportunity Identification

• 6 big losses

6 big losses are co-related with overall equipment effectiveness tool. Improve the equipment effectiveness with minimize the six big losses as per below.

  • Breakdown Loss
  • Set-up and adjustment loss
  • Minor stoppage loss
  • Reduced speed loss
  • Startup rejection
  • Production rejection

• 8 waste (MUDA)

8 waste is helpful to identify wasteful activities from operational processes. In a sort form 8 waste called as TIMWOODN. All the waste is categorized based on customer perspective. Review below attached 8 waste.

  • Transportation
  • Inventory
  • Motion
  • Waiting
  • Over-production
  • Over-processing
  • Defects
  • Non-utilize talent

• MURA

MURA is basically Japanese word and its meaning in English is unevenness. Due to variability in demand as well as production waste generation increases in operational process. Organization is focused to improve internal system to minimize unevenness and maintain process flow continuously.

• MURI

MURI is also a Japanese word and its meaning in English is overburden. It is also defined as overstress creation to processes and people, that leads to generate process waste. MURI examples such as un-necessary stress at workplace, due to improper instructions and proper training.

• 7QC tools

7 QC tools are deal with analyze and improve quality management system. With the help of 7QC tools very easy to take decision for quality improvements. Review below attached 7 QC tools.

  • Histogram
  • Pareto chart
  • Check sheet
  • Control chart
  • Scatter diagram
  • Cause and effect diagram
  • Flow diagram

Process Layout & Workstation Improvement

• Value stream mapping

The main objective of value stream mapping is optimizing plant layout, minimize overall customer order cycle time and utilize machines and other resources in effective way. It divided into two stages as per mention below.

  • Current state VSM
  • Future stage VSM.

• One-piece flow

one-piece flow is basically a concept related to combine all the individual workstation in a single path or with a minimum gap. The main key objective of one-piece flow is to minimize material handling and manufacturing lead time of workstation.

• Heijunka

Heijinka is a basically deal with production leveling. It helps to balance production between each workstation as well as interdepartmentally. Measure production leveling tool with the help of line efficiency and balance delay.

• Bottleneck Analysis

Bottleneck is a basically largest time consuming activity in a production process, if any organization structurally focused to analyze process and minimize bottleneck activity, then its directly impact on manufacturing lead time or customer order cycle time. for value stream mapping implementation bottleneck analysis is playing a vital role.

• Pull system

Pull system suggest to drive system through last stage. In traditional practice completely reverse strategy followed and due to that effect in increase of inventory level at workstation as well as also impact in customer demand not fulfilment.

• Cellular Manufacturing

Cellular manufacturing is basically a layout type of U shaped and each & every workstation are arranged close to each other. The key benefits for implementing cellular manufacturing is to minimize operator movement. It also improves team work within interdepartmentally.

Continuous Improvement

• Kaizen

Kaizen is a Japanese work and its meaning in English is continuous improvement. Involve people and developed continuous improvement system in organization. Target some processes and try to improve process with the help of lean manufacturing principles.

• Poka yoke

The exact meaning of poka yoke is error proofing techniques. Poka yoke concept is mainly used for improving performance of quality as well as safety. As per guidance of poka yoke concept developed structural system that zero percent chances of producing errors.

• Autonomation

The meaning of autonomation is automation with human touch. Now, in era of technology this tool suggests to avoid complete automation as well as also avoid completely manual repetitive tasks.

Equipment Performance Measurement & Improvement

• SMED

The basic concept of SMED is convert any process changeover into a single digit means, less than 10 min. bending machine changeover analysis, plate drilling machine changeover analysis, angle punching machine changeover analysis and many more.

• OEE

Overall equipment effectiveness is basically equipment performance measurement tools and its divided into three categories such as availability, performance and quality. Availability is a ratio of actual available time and planned available time. performance is a ratio of actual production time and actual available for production time. quality is a ratio of actual good parts produced and total parts produced.

• Total productive maintenance

TPM is a lean manufacturing tool related to machine management. The main objective of TPM is basically reduce the downtime of equipment and improve effectiveness of equipment. There are eight pillars of TPM as per mention below.

  • Jishu Hozen (autonomous maintenance)
  • Kobetsu kaizen
  • Early equipment management
  • Quality maintenance
  • Preventive maintenance
  • Education and training
  • Environment health and safety
  • Office TPM.

• Value added process

value added process means, think about the customer perspective not organizational perspective. Pick up one process for analysis perspective and check weather customer is paying to doing this process to make product or services, if answer is yes this process is value added process, if answer is no process is non value added process.

Quality Management

• Total quality management

TQM is basically approach to improve performance of quality across the organization. Customer satisfaction, total employee involvement, continual improvement, communication and fact based decision making is the primary goal of TQM concept.

• Root Cause Analysis

RCA is basically suggest to take decision based on facts rather than individual understandings. Basically why-why analysis and cause and effect analysis or fishbone diagram helps to reach at root of the live problems in the organizations.

• A3 problem solving

A3 problem solving tool is basically representation of overall problem solution in A3 sheet. It includes problem identification, data collection, project scope identification, root cause analysis, saving of project and many more data requirements.

Inventory Management & Process Standardization

• Kanban

Kanban is a visual instruction card, that flow with the material and it helps to instruct when to reorder item at workstation or store.

• Hoshin Kanri

Hoshin kanri is a basically policy development tool that helps to structural system development for strategic goals and breakthrough objectives of organization. Hoshin kanri provide system to communicate and drive organizational goals and objectives.

• Standardize work

Standardize work is basically a set of instructions for performing work in a best manner to minimize process waste as per process design. It helps to operator to new operator for performing an operation.

• Just in time:

Just in time is suggest to provide products and services to customers when they want. Avoiding more inventory at workplace and over-production activities. Focused to managing inventory at customer stage.

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Lean Manufacturing

Comments (33) on “Lean Manufacturing Tools”

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