Lean Concepts And Tools Pdf


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By definition, Kaizen includes the involvement of all employees, from upper management to assembly line workers and can be used to improve every process in a supply chain, from purchasing to logistics. Kaizen seeks to improve standardized processes in order to eliminate waste, fix workflow issues, and solve business problems. How is Kaizen implemented? The Kaizen method generally involves 5 primary steps:.

Lean Tools: The 7 “forgotten” techniques

Insight and Inspiration for Process Professionals. Lean Six Sigma has its origins in the electronics company Motorola. It is a powerful tool. Over the last few decades, companies all over the world have saved countless millions by incorporating Lean and Six Sigma strategies into their processes. It has a long record of being applied successfully across many industries. It is the combination of two different concepts, combined together to form a powerful tool to improve business processes.

Lean and Six Sigma. Lean refers to reducing waste in your business. Do you regularly wait for product shipments? Do processes go days without being actioned? Do products sit in a room until they are needed?

The purpose of lean management is to synchronize all of your business processes so there is no downtime and your operation runs as smoothly as possible. A lean approach will help your company eliminate activities that are devoid of value. A major benefit of lean is that you will deliver the same value to your customers but with less effort. A lean strategy will simply give your employees more time to spend on the value-adding processes that will add to your business's bottom line.

If lean is about streamlining processes, Six Sigma Is about improving the quality of what your business delivers, ensuring that variation is kept to a minimum. Six Sigma refers to a method of statistical quality control and is effectively a data-driven problem-solving methodology. The original definition is 3. Why such a precise figure and how does this relate to the corporate world? Six Sigma actually has its origins in the world of manufacturing. It is the mathematical symbol for a standard deviation sigma.

Six Sigma is the ideal acceptable range of deviation from an ideal mathematical measurement. Each level of Sigma allows a certain number of defects, with the number of defects reducing per level of sigma.

An occurrence that is six deviations from the mean should be incredibly rare, which works out to 3. That means Many companies take on Six Sigma because it sets a goal that is in the realms of perfection — but realistic enough giving employees across an organization the desire and motivation to meet it. Imagine if a busy train station had one million departures and arrivals every year.

At Sigma level 4 there would be mistakes. Is that good enough? Conversely, take a mobile phone which has thousands of components that must be assembled correctly to ensure the device works. A deviation worse than At the end of the day, the goal of Lean and Six Sigma is to eliminate waste , optimize processes, foster business process management and improve the quality of your product or service. To summarise, Lean aims to clean up the activities between the value-adding processes and Six Sigma is about improving the outcome of the processes and the work being done.

Lean Six Sigma is a must for businesses of every size as it makes quality a quantifiable statistic. It enables businesses to observe and study processes in a scientific way with the end goal of eliminating waste.

Interested in Lean Six Sigma? Learn more about what Lean Six Sigma is and find out 12 strategies to improve business processes. Learn More. Check out the picture below.

Waste is applicable to every industry and sector, from defence to hospitality. Here are examples of different kinds of waste and how they can affect your business. Defects are one of the most visible examples of waste and can be easy to grasp in any industry. Defects can cause waste in numerous ways in addition to the capital used to scrap or rebuild a product or service.

Defects will affect delivery times, logistics, and ultimately customer satisfaction. Your business should not spend an extra second on the rescheduling, paperwork and critical thinking that goes into fixing defects.

Overproduction occurs when you produce more product that is required by your customers. Companies tend to make the mistake of producing a product in large batches. This may seem like a good idea on paper, but market forces change and consumer needs change over time. Overproduction leads to excess inventory , which then leads to additional expenditure on storage space and preservation. This does not add value.

Nobody likes waiting. In a nutshell, waiting is the time it takes to begin another process after finishing one. The time spent waiting between processes and transactions will result in dissatisfied customers. There are innumerous benefits to recognizing the value of skills and ideas that improve a process, especially from employees on the frontline that see process waste on a daily basis.

A few examples include; a lack of teamwork, limited training, poor communication, duplicated administrative tasks and much more. Employee engagement, not micromanagement, is key to finding out how you can fix waste in your company. This comes in the form of moving a process from one individual to another, within the same department, and to another department. All of this adds unnecessary time onto a process. To eliminate this kind of waste, you can combine tasks and roles, and in extreme cases, reorganize workspaces to reduce physical movement.

Inventory waste occurs when a product or material is waiting to be sold. This is often the result of:. The difference between inventory waste and overproduction waste is that inventory waste is the value that is being held at a cost. Unlike overproduction, which assumed supplies exceed demand, inventory is material or product that has value but is not moving fast enough to meet customer demand.

Motion is any process that takes up time or capital by employees or machines, that fails to add value to the product being sold. The difference between motion and transportation waste is that motion waste is employee-centric and opposed to product-centric. Extra processing involves performing work on a product that does not conform to the customers' expectations. This often occurs due to the creation of multiple versions of the same task, process more than is required or long-winded poorly designed processes.

Examples include:. Cellular manufacturing is a lean manufacturing approach for process improvement. It is defined by two core characteristics. Grouped components and manufacturing cells. In cellular manufacturing , families of parts are created in a cell of machines. A cell is an area of production that is clearly defined and separated from other manufacturing cells — with each cell having ultimate responsibility for the family of parts and components.

Think of cells like mini production facilities within a larger production facility. It is an alternative to the traditional production line.

A production line refers to one continuous line of workers that add value to the product from receiving the raw material to the finished product. The major downside of a production line is that a disruption in any part of the line can halt the entire process as each component in the line relies on the components that precede it.

Cellular manufacturing involves the re-arrangement of workstations to facilitate production characterized continuous flow and less downtime. In the world of manufacturing, all operations and machines that are needed to produce a component a placed in close proximity.

By having equipment and workstations arranged in a sequence that supports logic, you can achieve one-piece flow. Also, know as single-piece flow and continuous flow, one-piece flow is when your products move through the manufacturing process at a rate determined by the needs of your customers. Takt Time refers to the rate at which a finished product is completed to meet customer demand.

It is an essential tool for discerning if goods a flowing from each station to the next in an efficient manner, ensuring that you can meet customer demand. The mathematical calculation for tact time is as follows:. The time available for production should reflect the number of time employees spending working on the product, minus variables such as meetings breaks, and other related activities.

Conversely, customer demand is a measure of how many products a customer expects to buy. Both of these variables should be consistent over the same time frame, such as one day or a week. It refers to the entire time span to create a product, from start to finish, ensuring that continuous flow is achieved and customer demand is satisfied. Takt Time is effectively your sell rate and is a good measurement of how efficient your work processes are.

Ideally, an optimal organization should have the capacity that can easily meet demand without having too much stock in inventory. Your company will be able to measure waste and easily discern which areas of production are struggling, on schedule, and otherwise need to be adjusted.

In this example, the customer will need one unit every seconds. However, you might like to produce a single unit in little less than seconds in order to accommodate any variation in process steps, it is vital that before you implement takt, you ensure that your processes are dependable and can deliver good quality and that your machine has a very high uptime.

Standardized work is a simple concept. It refers to the process of documenting methods, processes, materials, tools, processing times and more. At its core, it is about ensuring your operations run as smoothly as possible and your process improvement strategy is constantly evolving and being adopted by your employees. Standardized work is very important to reaching your ideal Takt Time.

Ensuring that your employees are using the best practices Is one of the best ways to increase efficiency. If you want to promote a working environment characterized by standardized work, you need to ensure that your standardization requirements are the reasonable and have scope for improvement.

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The Big Idea — Lean has a very extensive collection of tools and concepts. Surveying the most important of these, understanding both what they are and how they can help is an excellent way to get started. One way to start is to survey the most important lean tools, with a brief description and short explanation of how each tool can improve your manufacturing operations. If a tool captures your interest or resonates with you in some way — explore it further to decide if it is something to pursue now…or later. Many of these tools can be successfully used in isolation, which makes it much easier to get started. On the other hand, the benefits will compound as more tools are used, as they do support and reinforce each other. Eliminates waste that results from a poorly organized work area e.

Insight and Inspiration for Process Professionals. Lean Six Sigma has its origins in the electronics company Motorola. It is a powerful tool. Over the last few decades, companies all over the world have saved countless millions by incorporating Lean and Six Sigma strategies into their processes. It has a long record of being applied successfully across many industries. It is the combination of two different concepts, combined together to form a powerful tool to improve business processes. Lean and Six Sigma.

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Lean Manufacturing: Principles, Tools, and Methods. 1. Bosch Rexroth Corporation. 2. In today's manufacturing environment, assembly work is routinely​.


Six Sigma Tools & Techniques

What if you could reduce waste, increase efficiency and deliver more value to customers? The answer lies in Lean manufacturing. It sounds like an uphill battle, but with the right Lean manufacturing tools, driving out waste is easier than you might think. Sign up for a day free trial and you and your team can start building online Kanban boards today. Think of this article as a toolbox, from which you can pick and choose the right tools to use in your organization.

Top 25 Lean Tools

What Are Lean Tools?

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2 Comments

Rebecca R.
26.05.2021 at 09:54 - Reply

When talking about lean process improvement tools , many turn their eyes to Six Sigma , Kanban and even to lean canvas.

Christian G.
29.05.2021 at 17:04 - Reply

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