Lean Manufacturing - M.Ravichandran

Lean manufacturing is a series of methods, philosophies and tools used to eliminate waste or defects in a business while productivity is improving.

“Going lean” starts with eliminating waste to focus on added value to the process. There are several types of waste:

•  Defects
•  Overproduction
•  Waiting
•  Non-utilized talent
•  Transportation
•  Inventory
•  Motion
•  Extra Processing

 

Let’s have a look at lean tools and techniques to minimize waste and maximize production.

 

Kaizen: The “Kaizen” means the “change for the better.” The idea of Kaizen is continuous improvement. It makes teams work together proactively and take responsibility for the respective areas within the business.

 

5s System: The 5S system is a method deriving from five Japanese words: seiri, seiton, seiso, seiketsu and shitsuke. These words mean to organize, tidiness, clean, standardize and sustain.

 

Kanban: Kanban eliminates waste from inventory and overproduction by following a method for streamlining the flow of inputs.

 

Heijunka: Heijunka is a Japanese term for “leveling.” Leveling is a kind of process that manufactures products in smaller batches by sequencing varying products in the same process.

 

Just in Time (JIT): Just in Time is a management theory involving only on manufacturing a product when customer needs it without it being hung up in stock.

 

SMED: Single-minute exchange of dies (SMED) is a process used to greatly reduce the time it takes to complete equipment changeovers.

 

Poka-Yoke: Poka-Yoke – a Japanese term for "mistake proofing" – is a technique used to ensure lean process manufactures quality products. Its purpose is to minimize or eliminate defects by preventing, correcting, or bringing to light any human errors that are occurring.

 

While considering the implementation of lean manufacturing, it's essential to keep the lean manufacturing cycle in mind: Identify value, Map the value stream, Create flow, Establish pull and Strive for perfection.