Lean Tools Kit. IE Business School IMBA J4 Jan. 18

Organize the work area: Sort (eliminate that which is not needed)Set In Order (organize remaining items)Shine (clean and inspect work area)Standardize (write standards for above)Sustain (regularly apply the standards)How does 5S help?Eliminates waste that results from a poorly organized work area (e.g. wasting time looking for a tool).

idoka (Autonomation)What is Jidoka?Design equipment to partially automate the manufacturing process (partial automation is typically much less expensive than full automation) and to automatically stop when defects are detected.How does Jidoka help?After Jidoka, workers can frequently monitor multiple stations (reducing labor costs) and many quality issues can be detected immediately (improving quality).

Kaizen (Continuous Improvement)What is Kaizen?A strategy where employees work together proactively to achieve regular, incremental improvements in the manufacturing process.How does Kaizen help?Combines the collective talents of a company to create an engine for continually eliminating waste from manufacturing processes.

Kanban (Pull System)What is Kanban?A method of regulating the flow of goods both within the factory and with outside suppliers and customers. Based on automatic replenishment through signal cards that indicate when more goods are needed.How does Kanban help?Eliminates waste from inventory and overproduction. Can eliminate the need for physical inventories (instead relying on signal cards to indicate when more goods need to be ordered).

Poka-Yoke (Error Proofing)What is Poka-Yoke?Design error detection and prevention into production processes with the goal of achieving zero defects.How does Poka-Yoke help?It is difficult (and expensive) to find all defects through inspection, and correcting defects typically gets significantly more expensive at each stage of production.

PDCA (Plan, Do, Check, Act)What is PDCA?An iterative methodology for implementing improvements:Plan (establish plan and expected results)Do (implement plan)Check (verify expected results achieved)Act (review and assess; do it again)How does PDCA help?Applies a scientific approach to making improvements:Plan (develop a hypothesis)Do (run experiment)Check (evaluate results)Act (refine your experiment; try again)

Muda (Waste)What is Muda?Anything in the manufacturing process that does not add value from the customer’s perspective.How does Muda help?It doesn’t. Muda means ‘waste’. The elimination of muda (waste) is the primary focus of lean manufacturing.

Total Productive Maintenance (TPM)What is Total Productive Maintenance?A holistic approach to maintenance that focuses on proactive and preventative maintenance to maximize the operational time of equipment. TPM blurs the distinction between maintenance and production by placing a strong emphasis on empowering operators to help maintain their equipment.How does Total Productive Maintenance help?Creates a shared responsibility for equipment that encourages greater involvement by plant floor workers. In the right environment this can be very effective in improving productivity (increasing up time, reducing cycle times, and eliminating defects).

Heijunka (Level Scheduling)What is Heijunka?A form of production scheduling that purposely manufactures in much smaller batches by sequencing (mixing) product variants within the same process.How does Heijunka help?Reduces lead times (since each product or variant is manufactured more frequently) and inventory (since batches are smaller).

Single-Minute Exchange of Dies (SMED)What is Single-Minute Exchange of Dies?Reduce setup (changeover) time to less than 10 minutes. Techniques include:Convert setup steps to be external (performed while the process is running)Simplify internal setup (e.g. replace bolts with knobs and levers)Eliminate non-essential operationsCreate Standardized Work instructions

Just-In-Time (JIT)What is Just-In-Time?Pull parts through production based on customer demand instead of pushing parts through production based on projected demand. Relies on many lean tools, such asContinuous Flow, Heijunka, Kanban, Standardized Work and Takt Time How does Just-In-Time help?Highly effective in reducing inventory levels. Improves cash flow and reduces space requirements.

Value stream mapping is a lean manufacturing or lean enterprise technique used to document, analyze and improve the flow of information or materials required to produce a product or service for a customer. Full definition.———-Value stream mapping is a paper and pencil tool that helps you to see and understand the flow of material and information as a product or service makes its way through the value stream. Value stream mapping is typically used in Lean, it differs from the process mapping of Six Sigma in four ways:1) It gathers and displays a far broader range of information than a typical process map.2) It tends to be at a higher level (5-10 boxes) than many process maps.3) It tends to be used at a broader level, i.e. from receiving of raw material to delivery of finished goods.4) It tends to be used to identify where to focus future projects, subprojects, and/or kaizen events. Bottleneck AnalysisWhat is Bottleneck Analysis?Identify which part of the manufacturing process limits the overall throughput and improve the performance of that part of the process. How does Bottleneck Analysis help?Improves throughput by strengthening the weakest link in the manufacturing process. Continuous FlowWhat is Continuous Flow?Manufacturing where work-in-process smoothly flows through production with minimal (or no) buffers between steps of the manufacturing process. How does Continuous Flow help?Eliminates many forms of waste (e.g. inventory, waiting time, and transport).