Lean Manufacturing is a systematic approach toward business success and utilizes various Lean Tools for maximizing value and eliminating waste from a process and services to achieve perfection.
The main aim of lean manufacturing is to find better ways to eliminate lean waste and create value.
Lean manufacturing uses various lean manufacturing tools to improve quality, productivity, and efficiency through the effective utilization of resources.
There are various lean tools in manufacturing industries for continual improvement but 5S, Kaizen, Kanban, TPM, PDCA, and VSM are the most useful tools.
Table of Contents
Lean Manufacturing Principles | Lean Thinking | Philosophy
Lean Manufacturing follows the five lean principles defined by James Womack & Daniel Jones.
The five lean manufacturing principles are:
- Value identification
- Value Stream identification throughout the supply chain
- Flow-make the value flow
- Pull-Let the customer pull value
- Perfection-Strive for Perfection
>Explore Lean Manufacturing and Lean Principles for more details.
Lean Meaning | What is Lean in manufacturing?
Lean means the elimination of Waste or NVA (non-value-added activity) and adding value to processes and services.
Value in lean means any useful activities for which the customer is willing to pay.
Lean means in manufacturing is:
- Continual improvement in value-added activities, and
- Identification, reduction, or elimination of non-value activities(waste).
Lean tools in manufacturing | Tools for Lean | Lean tools list
The list of lean tools and techniques used in lean manufacturing, problem-solving, and 6 sigma methodologies are:
- 5S
- Kaizen
- VSM
- PDCA (Plan-Do-Check-Act)
- TPM(Total Productive Maintenance)
- Standardized Work
- Heijunka (Leveling Production)
- JIT(Just In Time)
- Jidoka(Autonomation)
- Poka-Yoke(Error Proofing)
- Kanban
- Takt Time
- Continuous Flow
- Cellular Manufacturing
- SMED(Single Minute Exchange of Dies)
- OEE
- Six Big Losses
- Andon
- Hoshin Kanri (Policy Deployment)
- Why-Why Analysis (5 Why Analysis)
- Gemba
- 3M Waste(Muda, Mura, Muri)
- SMART Goals
- KPIs (Key Performance Indicators)
- Visual Management
Lean tools | 5S
5S is a basic foundation stone of Lean manufacturing, TQM, and TPM methodologies. 5S is the first towards continuous improvement and an organization cannot succeed without lean 5S.
The 5S methodology is a systematic and continual improvement technique to eliminate the waste or non-value-added activities that originate from a poorly organized workplace.
It is an important basic tool of Lean manufacturing that improves workplace efficiency, adds value to the process/services, and provides a safe & hygienic environment.
The lean tool 5S includes five Japanese terms that all start with ‘S’
- Seiri – means sorting out or straightening up.
- Seiton – means putting things in order or systematic arrangement.
- Seiso – means clear up or clean the workplace.
- Seiketsu – means personal cleanliness or standardization.
- Shitsuke – means discipline or sustain.
>Explore 6S in lean (5S+Safety) for more details.
Lean tools | KAIZEN (Kaizen Blitz)
Kaizen is a continuous improvement process in daily working life, personal and social life.
Maiden’s philosophy is based on small continuous improvements in daily work rather than one large improvement at once. Kaizen’s belief is that the “small-small improvements in large numbers” at lower costs are generally better than some large improvements at a higher cost.
Lean Tools: Kaizen Meaning
KAIZEN is the Japanese word KAI and ZEN.
- Kai – means Change
- Zen – means Better
Therefore, Kaizen means change for the better.
>Explore Kaizen for more details.
VSM (Value Stream Mapping)
- Value Stream Mapping forms the basis of a Lean implementation plan.
- VSM helps to identify the values in the supply chain.
- Helps to visualize sources of waste & bottlenecks.
- Combine lean concepts together.
PDCA (Plan-Do-Check-Act)
Deming’s PDCA approach is based on continuous improvements. You can achieve desired results through effective and systematic planning, implementation, evaluation, and review process.
- Plan (Make a plan for desired results)
- Do (Implement plan)
- Check (Verify desired results achieved)
- Act (Review and do it again)
Lean Tools | TPM
TPM means Total Productive Maintenance aiming for zero machine trouble and maximizing overall equipment effectiveness.
Total Productive Maintenance is a method for continuously improving the efficiency and effectiveness of the manufacturing processes through effective TPM maintenance, and involving employees within the organization.
TPM manufacturing consists of 5S as a foundation tool and eight supporting pillars or activities.
The Eight Pillars of TPM are:
- Focused Improvement (Kobetsu Kaizen)
- Autonomous Maintenance (Jishu Hozen)
- Planned Maintenance
- Quality Maintenance
- Early Equipment Management
- Education and Training
- Office TPM
- Safety, Health & Environment
Poka-Yoke | Mistake Proofing | Error Proofing
The concept of Poka-Yoke was developed by Shigeo Shingo of Japan in the 1960s for preventing human errors.
Poka-Yoke is also called Mistake Proofing or Error Proofing.
The main objective of Poka Yoke is to prevent human and process errors in the first place, or at least easily detected and corrected so that mistakes do not turn into defects.
>Explore Poka-Yoke for more details.
Heijunka (Level Scheduling or Leveling Production)
Heijunka is a Japanese word for leveling production.
Heijunka reduces inventory (due to smaller batches) and lead times (since each product is produced more frequently).
The main aim of Heijunka is to leveling production by absorbing sudden fluctuations in customer demand.
It is a technique for reducing the 3M waste-Muda, Mura, and Muri.
Lean Tools | 3M Waste
The 3M concept is derived from Japan to identify and eliminate any kind of waste that is present in processes and services.
3M or 3MUs are– Muda, Mura, and Muri
- Muda– means Waste.
- Mura– means Inconsistency or Discrepancy.
- Muri– means Strain or Fatigue
>Explore 3M waste for more details.
JIT (Just In Time)
JIT is based on the Pull Concept.
Just-In-Time in lean production is defined as a “philosophy that focuses attention on eliminating NVA or Waste by purchasing or manufacturing of right items just in time”.
JIT refers to the production and supply of the required quantity of items when needed.
The goal of JIT is to reduce the levels of wasted materials, time, excess inventory, and efforts involved in the production process.
Kanban
Kanban means a Visual Card or Visual Record.
A Kanban system is a system of production and inventory control.
Kanban Signals,
- When to do work
- What work to do
- When not to do work
Jidoka (Autonomation)
Jidoka is also called Autonomation and is described as automation with human intelligence.
Jidoka is the ability for equipment/machines to be self-dependent and mistake/error-proof without any human interaction.
OEE (Overall Equipment Effectiveness)
OEE stands for Overall Equipment Effectiveness.
The Overall Equipment Effectiveness tool is used to monitor/improve the efficiency of the production process.
OEE definition
Overall Equipment Effectiveness (OEE) is defined as the product of three different measuring metrics.
- Availability: Actual production time out of total available production time.
- Performance: How fast the machine produced during the actual production time.
- Quality: Production of OK material out of total production.
OEE = Availability x Performance x Quality
For Example:
Availability = 95 %
Performance efficiency = 85%
Rate of quality = 97%
OEE = (.95 x .85 x .97)
OEE = 78.32%
Six Big Losses
The six major losses that are most common causes of waste in lean manufacturing are:
- Equipment Failure/Breakdowns.
- Set up and Adjustments.
- Idle and minor stoppage.
- Reduced speed.
- Defects in process.
- Reduced yields or start-up rejects.
All the above 6 big losses must be reduced from the manufacturing process to improve the organization’s OEE.
SMED (Single Minute Exchange of Dies)
Single-minute exchange of die is one of the important lean manufacturing techniques developed by Toyota Management for reducing/eliminating wasteful activities present in a manufacturing process.
SMED reduces changeover time to less than ten minutes.
Cellular Manufacturing
Cellular manufacturing is based on a group of various processes located in close proximity to manufacture a group of similar items/products. The primary purpose of cellular manufacturing is to lower the cycle time and inventories to satisfy customer demand.
Why Why Analysis | Root Cause Analysis-RCA
5 Why is a systematic problem-solving technique used to find out the real root cause by repeatedly asking “why?” deeper and deeper.
Because it is recommended to repeat at least five times, therefore it is known also as 5 Whys.
TAKT time
Takt time is the ratio of the Net time available for production to the customer’s demand.
It matches the pace of production with customer demands.
Takt time = Available work time per shift/Customer demand per shift
Example = 27000 seconds/600 pieces = 45 seconds
This means that one product is to be produced at a cycle time of 45 seconds to meet customers’ demands.
Standardized Work or Operations
Standardized work practice means that an organization must follow the documented procedures, SOPs, and WIs for manufacturing the products in order to reduce waste and improve quality, productivity, and enhance customer satisfaction.
SMART Goals
Every individual or organization has some targets or goals to achieve.
Goals can be achieved effectively and efficiently if defined in a SMART way and properly communicated.
SMART Goals means:
- Specific in nature
- Measurable
- Attainable
- Realistic
- Time-based
KPIs (Key Performance Indicators)
Key performance indicators of an organization are also known as performance objectives.
The KPIs or objectives are aligned with the company’s mission, policy, and goals.
Visual Management
The various names of visual management are:
- Visual Factory
- Visual Control
- Visual Work Place
Visual management includes – visual indicators, display boards, posters, and documents display throughout the organization to improve communication and provide information to follow or act upon.
Visual Management helps to sustain 5S, preventing accidents and highlighting the abnormalities at the workplace.
Gemba (The Real Work Place)
Gemba’s philosophy is to get out of the offices and spend your time on the shop floor to understand the actual situation/condition of a manufacturing process in order to identify the real root cause of problems.
It helps to provide a deeper understanding of real manufacturing issues – by self-observation and talking with shop floor workers.
Lean Tools | Hoshin Kanri (Policy Deployment)
Hoshin Kanri is also called Policy deployment.
Hoshin means Direction/Policy and Kanri means Management.
What is Hoshin Kanri?
Hoshin Kanri is the management tool that helps to keep the organization in the right direction
Hoshin planning helps to align the strategic goals of the company with the middle-level management’s plan(Tactics) and ensures that progress toward strategic goals is consistent and thorough.
Hoshin removes the waste that originates from poor communication or inconsistent direction.
Lean Tools | Andon
Andon is a Japanese term that means “Light” or “Lamp”.
Andon is a visual feedback system that is designed to stop the manufacturing process when a defect arises. The machine or work is stopped until the issue is resolved.
The goal of Andon is to improve the flow of communication when the actual problem occurs.
Types of Andon– typically there are two types of Andon system
- Manual- Operator controlled i.e. activated manually by operators either by pressing a static button or pulling the cord.
- Automatic- Machine controlled and activated automatically.
Lean Tools | Continuous Flow
Continuous flow means work in process flow smoothly through production with no or minimal buffers b/w steps of the production process.
The continuous flow system help to eliminate waste like inventory, transportation and waiting time, etc.
Lean Tools | Bottleneck Analysis
Bottleneck Analysis helps to identify the weakest link in the production process that limits the total throughput and strengthens the weakest link to improve the performance.
It is a structured approach to looking at the workflows and processes to address and rectify bottlenecks.
Bottleneck analysis saves an organization’s time, money, and energy by streamlining/improving the processes effectively and efficiently.
Recommended Lean Manufacturing books
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