18 Elements of Lean Production
Here is a reference guide to many things that come up on EfficicentFactory;
AWARENESS
1. 8 Kinds of Waste – elimination of waste including time motion and transportation
2. Management by Sight – Visual displays indicate exactly what is going on in the plant
3. 5S – The plant is clean There is a place for everything and everything is in its place
4. Team Focused Performance – Employees work in teams and are accountable for performance
5. Continuous Improvement Activity (Kaizen) – A Constant effort is being made to improve all aspects of the operation
JUST IN TIME
6. One Piece Flow – Striving to make number of pieces between each process as close to one as possible
7. Multi Process/Multi Machine – Operators perform multiple tasks on multiple machines within the work cell cycle time
8. Quick setup – Reduction of setup time to the most efficient it can be
9. TAKT Time – Customer requirements divided by time available in process
10. Standardized the work in repeated in the same manner shift to shift and person to preson
11. Pull System (KanBan) – Line operation is controlled by pulling product from previous process in controlled quantities
12. Work in process Management / First In First Out – Minimal inventory between processes. Product is being used on a FIFO basis
QUALITY
13. Failsafe Devices (Poka yoke) Devices are in place stopping product from being produced if a defect is found
14. Line Stop – Operators have the authority to stop the and correct the process if a defect is found
15. Root Cause Analysis – The Methods of analyzing a problem to find a root cause are being used on all issues
16. Total Preventative Maintenance – Majority of maintenance is scheduled through employee involvement
LOAD SMOOTHING
17. Load Smoothing – Production rate is leveled to demand and based on customer requirements (TAKT Time)
HEALTH AND SAFETY
18. Ergonomics – Ergonomic guidelines are applied to product equipment and tooling to prevent injury
Overall this a pretty good list. there are however amplifications on some of these themes. Stay tuned.
