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Lean Manufacturing Tools

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Lean Manufacturing Tools

Introduction

Main principle of lean

Lean methodologies.

Lean refers to the management practices that are used to improve efficiency and effectiveness through the elimination of waste in the manufacturing process. The main principle of lean is to eliminate all the non-value adding activities as well as waste. Lean manufacturing applies the techniques and activities that enhance the quality of the product (Sanders, Elangeswaran & Wulfsberg, 2016). Therefore, lean methodologies aim at minimizing waste while at the same time maximizing productivity.

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Principles of Lean Manufacturing

The principles of lean involves identifying value from the perspective of the customer, mapping the value stream which concerns the flow of material that is required in manufacturing a product. Creating flow to eliminate the functional barriers and establishing a pull of system is part of the principles. The last principle is seeking perfection for continuous improvement.

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Wastes Eliminated by Lean

The purpose of lean is to eliminate wastes. The wastes includes inventory, movement, defects, overburden, over processing, waiting transport. These wastes are incurred in the company out of unnecessary expenses. Avoiding these wastes makes the company have a competitive advantage over other companies in the same market hence generating income through the waste reduction.

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Steps of Lean Manufacturing Implementation

Identifying unwanted waste

Evaluating the wastes and to establish the root causes.

Coming up with solution to the problem

Applications of the problems in the problem solving tool to achieve results.

There are four steps of lean manufacturing implementation. The first is identifying unwanted waste. The most important thing for any manufacturing company is to have the processes efficient. Secondly, evaluating the wastes and to establish the root causes then coming up with a solution to the problem (Zahraee, 2016). Lastly, application of the problems in the problem-solving tool to achieve better results.

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Lean Tools

Kaizen tools

Kanban

Jidoka

Visual management

SMED

Kaizen is a lean tool that is used to bring about a continuous improvement in the quality of the products, the technology as well as the productivity of the firm. Kanban is a visual production system whereby the supply of the parts used in the production process is delivered as per their requirements. The main aim is to create efficiency. Jidoka manufacturing principle ensures that the quality of the products and the processes are automatically built into the production process. Visual management is an essential tool for lean manufacturing. it is used as a link between the data and the people.

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Workplace Organization of the 5S

Sorting which is the removing of the items which are not needed from the different work areas. Setting which is customizing the unique work areas so that their efficiencies are maximized. Shining is the cleaning of the different work areas after every work shift so that the issues that may arise are eliminated before major ones develop. Standardizing is the documentation of the improvements made on the work floor so that it becomes easier to apply them in other areas. Sustaining which the process that ensures that the steps are continuously repeated to bring about continuous improvements.

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Total Preventive Maintenance TPM

There are no breakdowns especially during the production process.

There are no small stoppages or slowdowns of the process which increases the lead time.

There are no defects in the process.

There are no accidents during the production process.

Total preventive maintenance is the principle that gives a holistic approach to the maintenance of the equipment. The main aim is to achieve perfect conditions in the production process. This principle aims at ensuring that; There are no breakdowns especially during the production process, there are no small stoppages or slowdowns of the process which increases the lead time, there are no defects in the process and there are no accidents during the production process.

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Pillars of Total Preventive Maintenance

Focus on autonomous maintenance.

Focus on improvement.

It uses planned maintenance.

It is involved in quality maintenance.

There must be proper training.

Offers office TPM.

Enhances safety, health and good environment

Therefore, when TPM is implemented in an organization, there is a sense of shared responsibility for the equipment and hence the floor workers must ensure the proper state of all the machinery (Lastra et al., 2019). When done correctly, this helps to enhance productivity by reducing the cycle times, eliminating defects, and increasing the uptime. The principles include: Focus on autonomous maintenance, Focus on improvement, It uses planned maintenance, It is involved in quality maintenance, There must be proper training, Offers office TPM and Enhances safety, health and good environment.

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Error-Proofing (Poka-Yoke)

Error proofing

Procedure for mistake proofing

Creating a flow chart of the process

to find the source of each of the errors that may occur in the process.

Error proofing or Poka-Yoke is a lean principle that is used in any device that is operated automatically. It is also used in a method that makes it impossible to detect the occurrence of an error so that it makes it obvious when it has occurred (Shenoy, 2016). Error proofing can be carried out by first of all creating a flow chart of the entire process. The main aim of this stage is to identify the areas where human error may occur. The second step is to find the source of each of the errors that may occur in the process.

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Set-up Education or SMED

Single Minute Exchange Dies is the principle that works on reducing the changeover time.

The key success of this principle is to move many setups from the internal setup to external

The formulation process of SMED.

- separating the internal from external setup operations

convert the internal to external setup

standardize the function of the machines and using f the clamps or eliminating fasteners

eliminate adjustments and mechanization.

Single Minute Exchange Dies is the principle that works on reducing the changeover time. It classifies the elements as external and internal to a machine operating time and hence classifying the external elements to be done externally. The main processes of SMED include separating the internal from external setup operations. The second step is to convert the internal to external setup. This is followed by standardizing the function of the machines and using f the clamps or eliminating fasteners. Then intermediate jigs must be used to adopt parallel operations. The other step is to eliminate adjustments and mechanization.

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Standardized Work

It used to establish the precise procedures that are used to make products in a way that is effective and safe based on the available technologies.

Benefits of standardized work

Reducing variability

Helping the people

Increasing safety

Standardized work in lean manufacturing is used to establish the precise procedures that are used to make products in a way that is effective and safe based on the available technologies (Shafeek, Bahaitham&Soltan, 2018). The benefits of standardized work include Reducing variability, Helping the people and Increasing safety.

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Line Balancing or TAKT Time

Takt time is equal to the production time, then the production line is balanced.

Benefits of line balancing

Reducing waste

Reducing inventory waste

Absorbing internal and external irregualarities

Reduction of costs of production and increasing profits

Batch size reduction

Line balancing refers to the production strategies that involve balancing the operator and the machine so that they match the Takt time. The Takt time is the rate at which the products are produced as per the demands of the customers (Adnan, Arbaai & Ismail, 2016). When the Takt time is equal to the production time, then the production line is balanced. Benefits of line balancing includes Reducing waste, Reducing inventory waste, Absorbing internal and external irregularities, Reduction of costs of production and increasing profits and Batch size reduction.

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Heijunaka and the Process

This is a Japanese lean methodology that aims at improving the processes. It helps the firms to match the unpredictable demand and to eliminate the manufacturing waste by leveling the type and the quantity that should be produced. This methodology is great because it helps in avoiding the inefficiencies which are present in the manufacturing process of large batches. The methodology makes it possible to put the production process closer to customer demands (Araujo et al., 2018).

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Cellular Manufacturing

Cellular manufacturing is used when the equipment is arranged into workstations which facilitate the production of small batches in a continuous production flow. The workstations which are known as cells are U-shaped so that there is quick feedback between operators. Whenever an issue arises, there is a fast response and those workers who are trained within the cell can perform multiple tasks (Khalid et al., 2019). Therefore, this is a process that helps to minimize the downtime and ensures that the continuous flow of products is enhanced. As a result, there are minimum waste and high efficiencies

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Just In Time

Just-in-Time manufacturing is a methodology that is used to reduce the flow times in the production systems (Pinto et al., 2018).

Benefits of JIT.

Reducing inventory.

Reducing the labor costs.

Reducing the space on the work floor.

Improving the quality of the product.

Reducing the standard hours\reducing throughput time.

Increasing shipment

Therefore, Just-in-Time manufacturing is a methodology that is used to reduce the flow times in the production systems (Pinto et al., 2018). It helps to control the variability in the processes and allow for an increase in productivity while at the same time lowering the costs. Some of the benefits includes: Reducing inventory. Reducing the labor costs. Reducing the space on the work floor. Improving the quality of the product. Reducing the standard hours\reducing throughput time. Increasing shipment

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Conclusion

The concept of lean

The lean tools

The wastes eliminated by lean

The concept of lean in the manufacturing setup is meant to reduce the wastes and increase the efficiency of the processes. Therefore, this is an approach used in manufacturing to reduce variability and increase productivity. Several methodologies are used to enhance the quality of products and minimize waste. These include Kaizen, Kanban, line balancing, and Takt time, as well as preventive maintenance. Some of the wastes that must be eliminated include waste of motion, inventory waste, waste of overproduction, and waste of over-processing.

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References

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Araujo, G. P., Cesar, F. I. G., da Silva, A. L., & de ArrudaIgnácio, P. S. (2018).Application of heijunka leveling in a medical devices company. Journal of Lean Systems, 3(3), 02-23.

Chan, C. O., &Tay, H. L. (2018).Combining lean tools application in kaizen: a field study on the printing industry. International Journal of Productivity and Performance Management.

Eaidgah, Y., Maki, A. A., Kurczewski, K., &Abdekhodaee, A. (2016).Visual management, performance management, and continuous improvement. International Journal of Lean Six Sigma.

Kamble, S., Gunasekaran, A., &Dhone, N. C. (2020). Industry 4.0 and lean manufacturing practices for sustainable organizational performance in Indian manufacturing companies. International Journal of Production Research, 58(5), 1319-1337.

Khalid, Q. S., Arshad, M., Maqsood, S., Jahanzaib, M., Babar, A. R., Khan, I., ...& Kim, S. (2019). Hybrid Particle swarm algorithm for products’ scheduling problems in the cellular manufacturing system. Symmetry, 11(6), 729.

Lastra, F., Meneses, N., Altamirano, E., Raymundo, C., &Moguerza, J. M. (2019, July).Production management model based on lean manufacturing for cost reduction in the timber sector in Peru.In International Conference on Applied Human Factors and Ergonomics (pp. 467-476).Springer, Cham.

Lazarevic, M., Mandic, J., Sremcev, N., Vukelic, D., &Debevec, M. (2019). A systematic literature review of Poka-Yoke and a novel approach to theoretical aspects. StrojniskiVestnik-Journal of Mechanical Engineering (in press).

Maalouf, M. M., &Zaduminska, M. (2019).A case study of VSM and SMED in the food processing industry. Management and Production Engineering Review, 10, 60-68.

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Nallusamy, S. (2016).Productivity enhancement in a small scale manufacturing unit through proposed line balancing and cellular layout. International Journal of Performability Engineering, 12(6), 523-534.

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