Lean Manufacturing Tools

Value Stream Mapping (VSM)  Value Stream Mapping (VSM) in lean: Value stream mapping is a popular lean manufacturing tool. Value-stream mapping, also known as material- and information-flow mapping. It is used to analyze the flow of materials and information required to produce a product or service from start to finish. It is a flow diagram of every step of a process which is used to identify waste, reduce cycle times, and implement action plan for improvement. Value Stream Mapping (VSM) is a visual representation of a process to identify waste and opportunities for improvement. Why Value Stream Mapping (VSM)? The objective of value stream mapping is to identify opportunities for improvement and to eliminate waste in the process.(7 Wastes of Lean: Transportation, Inventory, Motion, Waiting, Overproduction, Over-processing, and Defects). The value stream map indicates what the process is ? It shows all of the steps in the process, including the inputs, outputs, and cycle times for e...

Problem-solving : It involves a structured approach to identify, analyze, and resolve production issues. 5 C's of problem-solving: The 5Cs are  1)Conditions,  2) Correlations,  3) Contributions,  4) Causes, and  5) Corrections. Problem-Solving Techniques: Trial and Error: Testing different methods for a solution to problem. Lateral Thinking:  Using unconventional approach or angles for  the problems. Divide and Conquer: Breaking down large/complex problems into smaller/manageable parts. 5 Whys: Ask "why" repeatedly to find out the root cause. Fishbone Diagram : Visually mapping out  causes of a problem to identify root issues. Also known as 'Ishikawa'. Working Backwards: Starting with the desired final result and work backward to determine the steps required to reach desired result. SWOT Analysis: By evaluating the Strengths, Weaknesses, Opportunities, and Threats related to a potential solution. PDCA Cycle (Plan-Do-Check-Act): A four-step  ...

Poka-Yoke: Poka-yoke is a Japanese term developed by Shegio Shingo. Poka-yoke means mistake proofing  (error-proofing). Poka-yoke is to identify and eliminate potential errors before they occur. Poka-yoke is making mistakes impossible. Poka-yoke is use of devices or method or designing systems or processes to make mistakes impossible. Types of poka-yoke: Contact methods Fixed-value methods Motion-step methods 1.Contact methods: These devices prevent errors by detecting abnormalities or deviations in the process . Example 1- A machine may have sensors that signals when a part is not at proper position.  Machine stops before it can cause a problem. These Poka-yoke prevents further actions untill part position is corrected. 2.Fixed-value methods:  These types of poka-yoke are designed with fixed values or constraints that prevent errors to happen.  Example 1- A machine may have logics in programming that signals when a tool is wear out after specific number of machining...

  Gemba: "Gemba," means  going to the place where work is being done, to observe and understand the work processes and identify opportunities for improvement at the actual workplace. During a Gemba walk, team leader visits the work area and observers the processes, asking questions and listening to employee feedback.  Leaders collects information and uses it to guide an improvement cycle. By engaging in Gemba walks, organizations can foster a culture of continuous improvement. Gemba! That's a Japanese term that roughly translates to "the real place" or "the place where work is done." In business and management, Gemba refers to the idea of going to the actual workplace to observe, learn, and improve processes. Gemba Walk: A Gemba walk is a technique used to: 1. *Observe processes*: See firsthand how work is being done. 2. *Identify waste*: Look for inefficiencies, bottlenecks, and areas for improvement. 3. *Engage with employees*: Talk to workers, ask q...

Kanban- Kanban is a Japanese word which is meant for "visual card". Kanban also known as Toyota Nameplate System is a lean continuous improvement tool that tracks production within a factory in the automotive industry  Taiichi Ohno developed Kanban to improve manufacturing efficiency.  Kanban is a scheduling system for lean manufacturing. Kanban is used to manage and control inventory levels, WIP (work-in-progress) and production flow, The Kanban system uses visual signals, such as cards or boards. Cards or boards indicate inventory and production status.   Today, many organizations use digital Kanban boards. Digital Kanban boards are used. to visualize work-in-progress. Kanban helps to eliminatie bottleneck  .by creating exact quantity which is needed by the next step in the process,   Concept of Kanban: Kanban is a visual workflow management system used to manage and track work as it progresses through a process.  Kanban boards are  key com...

Kaizen-The Japanese Methodology: Kaizen is a Japanese word. Kaizen is the Japanese methodology used in lean manufacturing techniques. Kaizen means good change or "Continuous Improvement" .  Kaizen is a  method for improving processes with small but incremental changes over time. Kaizen Benefits: to eliminate waste. to optimize efficiency. to improve quality. to empower employees . Kaizen is a method to encourage employees to work together to make small but regular improvements in business processes. Kaizen is a Japanese  philosophy that encourages continuous improvement by  all employees involvement.It is a long-term approach to small but incremental improvements. 5 in Kaizen or Steps in Kaizen technique: 1)Identifying problems 2)Analyzing the current process 3)Brainstorming the solutions and selecting the best solution. 4)Implementing the best solution into practice 5)Reviewing the results and Standardizing the solution as a part of ongoing processes. ORIGIN OF KAIZ...

SMED: SMED (Single Minute Exchange of Die): SMED  stands for  Single Minute Exchange of Die. SMED (Single-Minute Exchange of Die)  is a Lean tool used in manufacturing to reduce equipment changeover time.  The goal of  SMED  is to complete as many steps as possible while the equipment is running , to save time and quickly change over to processing the next product. The core principles of the  SMED  procedure involve separating changeover elements into two categories. Internal activities and External activities. For  SMED : Internal activities  -  can only be performed when the production process is stopped. External activities-  can be completed while the machine running or upto the actual changeover begins.  SMED  helps in achievement of  rapid setups and minimized downtime by  converting internal activities into external activities. Advantages of the SMED: Reduced changeover times / Reduced Downtime by min...

OEE (Overall Equipment Effectiveness): What Is OEE?  OEE full form is Overall Equipment Effectiveness. OEE (Overall Equipment Effectiveness) is a fundamental principle of Lean Manufacturing, OEE (Overall Equipment Effectiveness) is a universal “best practice” metric to monitor, evaluate, and improve the effectiveness of a production .  OEE (Overall Equipment Effectiveness)  is  the percentage of planned production time that is truly productive. OEE in lean manufacturing means  manufacturing  good parts as fast as possible, with no downtime. OEE is  originally developed by JIPM (Japan Institute of Plant Maintenance) . OEE score of 100% represents perfect production:  OEE (Overall Equipment Effectiveness)  in manufacturing is a lean tool used in Total Productive Maintenance programs.  OEE Formula : OEE is a combination of three factors. Standard OEE formula is tabled by Nakajima. OEE (Overall Equipment Effectiveness ) is calculated as...

PPE : PPE full form : Personal Protective Equipment. PPE means Personal Protective Equipment. Personal protective equipment (PPE) refers to protective clothings, helmets, gloves, face shields, goggles, facemasks, earplugs, muffs, coveralls, vests, full body suits,  high visibility suits, safety harnesses, respirators or other equipments designed for protection from injury ,infection, illnes or exposure to a variety of hazards. Why PPE: To promote good Hygiene To prevent Hazards To reduce spread of infection To enhance workplace safety To protect Lives   To comply businesses with regulatory requirements(e.g., The Personal Protective Equipment at Work Regulations 1992) To improve employee efficiency. Types of Protection: 1) Respiratory Protection: Protection against the adverse health effects caused by breathing contaminated air. Examples:Respirators. 2) Eye & Face Protection: Eye and face protection from the hazards of  hot sparks, and chemical splashes  flyi...

Industrial safety - Industrial safety  leads to ZERO ACCIDENT GOAL   of every organisation. Everyone working in the industries must follow Industrial safety rules. Creating and maintaining protective, safe and efficient workplace environment is the major role played by Industrial safety Management team. Workplace safety is very important for each and every employee to work in a safe and protected atmosphere. What is meant for term  safety  in  Industrial safety? Safety means a state of being safe from the risk of loss or danger. Safety plays a vital role in industry by protecting employees and assets by minimizing hazards, risks, accidents, and near misses. Safety is a condition that gives you freedom from hazards, risks, and accidents that may cause injury, damage, loss of material or property damage, and even death. Elimination of hazard is also known as safety.  Safe and healthy workplace protects workers from injury and illness which reduces absen...

How to eliminate bottleneck. In previous artcle we discussed about bottleneck in production process. Now we will see How to eliminate bottleneck ? How to eliminate bottleneck is very important in manufacturing. Bottleneck removal in lean manufacturing is a very crucial task for management. How to eliminate bottleneck in manufacturing is important not only for productivity but also for smooth operations flow on line. For reducing WIP on production line, it is the important question that... How to eliminate bottleneck? Bottleneck analysis is important for the bottleneck elimination in manufacturing. How to eliminate bottleneck  in production line without having much inventory in process line is target for management.  Following are some goals of the bottleneck analysis. GOALS OF THE BOTTLENECK ANALYSIS : Identification of the key bottlenecks in manufacturing process. Relevant quantitative data collection for bottlneck analysis. Exploring possible solutions for bottleneck root c...

BOTTLENECK IN PRODUCTION PROCESS- Bottleneck in production process , is a process whose limited capacity reduces, delays or stops the flow of operation and affects the capacity of overall manufacturing processes.   Almost every system has a bottleneck . The machine with the longest queue of accumulated input for processing is usually a bottleneck in production process. It is important to identify the bottleneck machine or process and to remove or reduce the waiting time for next operation so as to achieve the desired targets in manufacturing processes. Here discussed the various types of   bottleneck in production process. Types of Bottleneck in production process: 1.Short-term Bottleneck:  These are caused by temporary problems.  Short-term bottlenecks  do not need regular attention. 2.Long-term Bottleneck:   Long-term bottlenecks occur all the time. These have substantial impacts on the overall manufacturing processes.  Long-term bottl...

L ean management in the pharmaceutical industry and COVID 19. The pharma companies manufacturing the vaccine for  Covid-19 has to follow strictly the lean manufacturing principles to eliminate non value added work so as to achieve the demand raised in this panademics of COVID-19 . For the organizations like Serum Institute of India, Lean Manucturing tools will help to do value added acts every time so as to meet the demand of vaccine in India and other countries. On time and quality production of vaccine with reduced associated costs will help the organizations like SERUM & PFIZER to meet the expectations of people of the whole world's  and high demand. Also Lean tools will results in reduced prices of the vaccine. The pharma industries must achieve Zero Losses due to downtime & minor stoppages so as to meet the demand of vaccine. Reduced manufacturing cost is going to help to provide the vaccine to the Governments with reduced cost and so the distribution amongst the ...

Equipment Safety : The protections used at workstation so as to avoid danger for human body that is workmen along with the equipment and leading to safe work is termed as equipment safety. Equipment safety is important for long life of workmen and so as equipment by avoiding accidents at workstation during processes. Thus equipment safety becomes valuable in manufacturing industry. Following factors are important to confirm equipment safety: 1. Make sure that the equipment is safe for any work.  2. Make sure that the equipment is safe for carrying out breakdowns repairs, and preventive or planned maintenance. 3. Make sure the equipment is properly switched off, isolated or locked-off before taking any action to remove blockages. 4. Make sure that the equipment is with no risk of electrical, hydraulic or pneumatic power supplies. 5. Make sure that equipment is with no badly designed safeguards.  6. Ensure No sharp edges or corners associated with equipment. 7. Check that the ...

Factors Affecting Basic Work Content -   Basic work content is the minimum time required for production as per standard rate of working with the help of qualified worker and with perfect design and specifications. The heart of the productivity improvement in any manufacturing organisation is depend on its basic work content. Process of manufacturing is affected by some factors associated with basic work content. Following are the factors affecting basic work content and thus on the productivity. 1.Workmen Efficiency: Workmen enfluencing basic work content in following ways-  Careless workemenship  Accidents by workmen. Absentism of workmen. Idleness of workmen. Lateness of workmen. Indisciplined workmen.   2.Management Shortcomings: Management is also responsible for enfluence on basic work content . Some management shortcomings are as - Design changes. Excess product variety Bad planning. Lack of standardization. Plant Breakdowns.   Bad working conditions...

JIT and Advantages Of JIT (Just In Time) Manufacturing: JIT (Just In Time) manufacturing is very benificial for lean manufacturing. The benifits of JIT for manufacturing industries are a lot. Some of the advantages of JIT in manufacturing are as follows- Lesser Cost Of Production. Less working capital is required to finance for procurement.  Minimum re-order level. Works on a demand-pull basis, in the volatile and unpredictable market demand. Inspection costs and Rework costs are minimized. High customer satisfaction due to constant communication with the customer. Reduction in Manufacturing Lead Time and Increased Conformance to Delivery Lead Time. Reduction in Inventory Investment and Increased Investment Savings. Increased Revenue and High ROI (Return On Investments). Increased Response Speed to Market Needs. Close relationships and Improved Workforce Morales. Uncovering of Problems. Keeps stock holding costs minimum and better space utilization with Low or No warehousing cost. ...