Lean tools ppt

What is Lean? Process walks 8. Pareto Charts 9. PDCA Brainstorming Process Mapping Spaghetti Diagrams Histograms Check sheets Flowcharts Takt time Tasha Oliva Dec.

Did u try to use external powers for studying? They helped me a lot once. PrimalkaDias Aug. Hassan Hannoura Jun. PantherTeamME Apr. Kapil kumar saini Feb. Show More. Total views. Different colored lights are used to signal different problems and actions required.

Operators may turn on an Andon in order to signal that there is a problem in an assembly line. In an office setting, a red colored light Andon may signal that a fax machine or printer is broken. Andons work best when they are highly visible and easy to understand. They must go hand in hand with an action. So, for example, an Andon warning light on a car that signals low gas, would indicate a clear action: fill up the tank with more gas.

Source: agileleanhouse. What is Gemba? Gemba Walks refer staff taking the time to walk through the factory, examine what is going on, and determine if there are any issues. In the lean management philosophy, staff are expected to do Gemba Walks at least once a week. What is Hoshin Kanri? What is the goal of Hoshin Kanri? The goal of Hoshin Kanri is to determine your strategic objectives and then align them with specific resources and action plans to meet those objectives. Source: wikihow.

OEE is a system used to measure manufacturing productivity. It measures the percentage of time that a manufacturer is truly productive. OEE includes measurement of quality, performance, and availability.

By measuring productivity in terms of time, manufacturers can gain insight into how to improve overall manufacturing performance. The system helps to identify waste, track progress, and improve manufacturing equipment efficiency. Cellular Manufacturing is the process of producing similar products in one cell.

The product, in Cellular Manufacturing, moves through the production process in a single unit without interruptions. In Cellular Manufacturing, similar products can be produced on the same assembly line.

Example of Cellular Manufacturing? A metallic case arrives in a factory and needs to be assembled. Assembly requires a variety of different steps. The goal of Cellular Manufacturing is for all the steps to occur in one area, in a single cell. This reduces the time it takes to transport the parts during the production process. Source: mktgcdn. Continuous Improvement is a methodology within lean manufacturing that advocates following formal practices to improve efficiency over time.

How is Continuous Improvement implemented? Continuous Improvement is implemented in four steps:. Source: nevilleclarke. Total Productive Maintenance is a lean tool used to prevent machine downtime within the production process. The goal is to limit downtime as much as possible in order to increase production efficiency. Total Productive Maintenance includes three main components:. Source: smartsheet. Total Quality Management is an organizational effort to improve the quality of a manufactured product.

The goal is to increase quality of every single step in an organizational workflow. What are the origins of Total Quality Management? It was later used by Japanese Manufacturers and implemented on a mass scale in the s. There are a few main principles of Total Quality Management:. Source: apollorootcause. Root Cause Analysis is a lean problem solving method that aims to get to the root of a problem. By treating the root cause, manufacturers can eliminate larger problems down the road.

Still, Root Cause Analysis will generally not fix problems in one try and is generally an iterative process. Value Stream Mapping is a lean tool that uses a flow diagram to depict every step of a process.

What is Value Stream Mapping applicable to? Value Stream Mapping can be applicable in almost any industry, but it is primarily used for: logistics, supply chain, product development, and administrative processes.

What data should be collected to create a Value Stream Mapping? Some data points to collect for Value Stream Mapping include:. Source: agilelea.

Continuous Flow is the opposite of batch production and is closely associated with Kanban and Just-in-Time. The goal of Continuous Flow is to use ongoing examination and improvement to integrate all elements of production. By aiming for a Continuous Flow production process, waste and other problems come to the surface and can then be solved. Ultimately, many lean principles and tools center around creating a Continuous Flow production process.

Areas like oil refining, metal smelting, and natural gas processing are ideal for the Continuous Flow process. A Lean Audit is a tool used to determine how well lean manufacturing principles are working in a factory or company. Changeover is the amount of time it takes to change a piece of equipment between the production of one item to the next. In Lean, the goal is to ensure a Quick Changeover.

A pit-crew at a car race is a great example of Quick Changeover. The quicker a crew can a changeover, the better chance a racer has of winning. A slow changeover will often result in losing a race. Right First Time is a lean philosophy that stresses getting processes right the first time, every time.

The concept involves planning and a deep understanding of manufacturing processes. In lean manufacturing, 7 Wastes refers to seven typical places manufacturers have waste. Using the 7 Wastes tool, manufacturers can determine where they have waste and can improve their processes in each area.

The method was invested by Toyota and is an integral part of the Toyota production system. Source : e-qms. Six Big Losses refers to the six most common reasons for ineffective production.

In order to effectively use lean manufacturing methods, management must set proper goals strive for. Ideally, those goals should be clearly defined and communicated. In order for a goal to be achieved it should be:. KPI is an acronym for Key Performance Metric and it refers to metrics used to assess and analyze manufacturing efficiency. KPIs are essentially metrics set by management in order to measure the success of lean manufacturing goals.

The goal of SMED is to get all changeovers and startups down to 10 minutes. Each step should be one minute or less. By reducing setup time, factories can greatly improve efficiency. What are the steps to implement SMED? The steps to perform SMED are as follows:. Source: sixsigmaconcept. A3 Problem Solving is a problem solving method that uses a structured, continued growth methodology to improve manufacturing practices.

The method was invented by Toyota and is based on the work of Edward Deming. The PDCA method is a cycle and is repeated over and over again in order to drive continuous improvement. Source: truenorththinking. Standardized Work is a tool used to document current best practices, improve the standard, and ensure that the new standard becomes a baseline for improvement. Standardized Work improves 3 important aspects of the manufacturing process:.

What are the benefits of Standardized Work? The main benefits of Standardized Work include:. Source: qualityaretegroup. This process continues until a conclusion is reached. The 5 Whys technique was developed by Sakichi Toyoda and has been used by Toyota to improve its manufacturing processes.

The 5 Whys technique generally requires persistence and determination for it to work effectively. In order to properly perform 5 Whys, managers should follow a variety of rules:. Hartford Technologies, Inc.

All rights reserved. Tel: info hartfordtechnologies. Hartford Technologies Blog. Posted: Oct 19, PM. The Kaizen method generally involves 5 primary steps: Identify problem area that will be given focus. Utilize videotape to analyze current method. Test and evaluate improvement tactics.

Implement improvements. Analyze results and present to upper management for feedback. What is Kaizen most applicable to? What are the advantages of One-Piece Flow? The advantages are: Ability to detect defects earlier and more accurately. More flexibility for customization and meeting customer demands. Reduces costs by eliminating waste. Reduce the amount of work in progress to make each step more efficient.

Easier to predict shipment times. What are the principles of Jidoka? The principles can be broken down into four steps: Discover an abnormality or problem. Stop the operation process. Fix the problem at hand. Discover the root cause to prevent future issues. Why use Poka Yoke?

Visual Management is a communication technique that uses visual aids to convey messages quicker and more efficiently What is the goal of Visual Management?

The objectives of Visual Management are: Clarify waste. Display problems in a simpler way. Clearly indicate your efficiency goals. Increase effective communication. Lessen investment in inventory. Create a more effective balance between supply and demand. What is the history of Just in Time? Takt creates a rhythm across a supply chain to ensure continuous flow and full utilization of available resources.

Bottleneck or constraint in a supply chain refers to the resource that takes the longest time in operations. When hiking, for example, a bottleneck refers to the slowest member of a hiking group. That member can determine the speed of the entire group. The same goes for processes in manufacturing. If one part of a supply chain is unnecessarily slow, it can reduce the speed and efficiency of the entire manufacturing process. The goal of Bottleneck Analysis? The goal of Bottleneck Analysis is to determine the slowest parts of the manufacturing process and then figure out how to speed them up.

The process can be costly, but will usually lead to increased efficiency and profits. Ignoring a bottleneck issue can be very costly down the line.

Andon is a signaling system used in the manufacturing process when there is an abnormality or some sort of important action is required. It is a form of visual management. In manufacturing, it refers to the factory floor. It can also be a construction site, sales floor, etc. The idea of Gemba in lean manufacturing is that management must go to factory floor to search and fix visible problems.

Manufacturing problems, Gemba argues, cannot be solved from an office. They require an actual physical presence by problem solvers on the manufacturing floor. How does Continuous flow help? Heijunka Level Scheduling Heijunka means sequencing, or smoothing of production. By multiplying the tasks, and distributing them better, and by standardising them by carefully-studied smoothing, better use can be made of the working time available for creating value.

Work is appropriately distributed and no individual has too much or too little work. How does Heijunka help? How does Jidoka help? Helps in saving time and waste of raw material. How does Just In Time Help?

Hence, reduces the storage space. How does Kaizen Help? Poka Yoke Mistake Proofing Ensure that the process is error free and stays that way.

How does Poka Yoke help? How does VSM help? Data for KPIs are valid - data should be meaningful, timely and reliable for sound management decision-making.

KPI must be a metric that will drive strategic competitive advantage for the organization. How does Visual Management help? Kanban Pull System Replacing only what has been consumed and only what is immediately deliverable. How does Pull System help? Bridget Moore Dec. They know how to do an amazing essay, research papers or dissertations. Zeel Patel Aug. ShubhamTyagi Jan.

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