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It means the way that processes are evaluated, monitored, improved and stabilized.
The main tools are:
- TPM (Total Productive Maintenance)
- Poka yoke
- SMED (Single Minute Exchange of Dies)
- Graphical work instruction
- Visual control
- Continuous improvement
- Line stop
- 5S
Metrics
It means the way of how is physically and concretely measured the performance, improvements and
team recognition.
The main tools are:
- On time delivery
- Process lead time
- Total cost
- Quality yield
- Inventory
- Space utilization
- Travel distance
- Productivity
Logistics
It means the way that are developed, improved and controlled physical flow activities of planning and
controlling.
- Forward plan
- Mix-model manufacturing ability
- Level loading
- Workable work
- Kanban pull signal
- ABC products handling (ABC Method)
- Service level
- Client supplier alignment
- Operational rules
The lean manufacturing approach is based on :
- Project management tools and methodologies,
- Continuous analysis (Kaisen),
- Continuous control (5S and Poka Yoke)
- Pull production application.
Lean methodology project applies the following steps :
- Lean Assessment focused on waste opportunities
- Current state gap
- Future state design
- Deployment
- Results assessment
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Involvement of all studied activities managers and of direction board is an important vector of
success and ensure the identified changes opportunities adequacy with customers expectations.
At the end of deployment a sustained change will be insured by a permanent control:
- Management realizes 5S audit at least once a month
- Operational workers are animated trough continuous improvement activities
- Operational teams conduct Kaisen event every quarter
- Operational KPIs are updated every day
- Operational problems are reviewed every day
- Operational meeting every day to review progress and issues
- Setup times are recorded
- Training level evaluation matrices are updated every quarter
- Equipment is cleaned and checked every day
- Customers and suppliers are visited by operational team members every quarter.
Examples of Lean Manufacturing results
Lean Manufacturing approach improves:
Operations
o More Productivity
o Lead Time reduction
o Inventory reduction
o Surfaces need reduction
o Launching process time reduction
o Low quality costs reduction
People
o Efficient and coordinate Communication
o Efficiency
o Autonomy
o Competence
o Low security risk
o Motivation
To clients
o Reactivity in answering the needs
o Flexibility
o Service
o Confidence
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