Lean Manufacturing Tools for Beginners


 
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Lean Manufacturing Tools for Beginners
Paul Ryan, Other, Ireland

Could somebody tell me what are the most important lean tools and techniques that should be used in a company that are about to implement lean manufacturing for the first time? Why? Thank you for your suggestions.

 
 
Lean Manufacturing Tools for Beginners
Eric Schmitz, Other, Belgium
First of all, there is no standard way. Each company has to go his own way, based on his own culture, people, market and so on.
Then, before the start management and staff should understand very well the thinking behind lean. I would suggest to read 'Lean Thinking' Womack and Jones (surely the first 100 pages) in order to understand the basic concept of value - valuestream - flow - pull - ci.
Also I suggest to read - but this can be in the implementation phase - 'The Toyota Way'.
Be sure that management and staff is aware and motivated to go ahead.
 

 
Lean Manufacturing Tools for Beginners
Eric Schmitz, Other, Belgium
Step 1: 5S Framework. Why?
- Involves every one
- Is very visible
- Push for supervisors and management to delegate
- Start of teamwork and working together.
Step 2: Value Stream Mapping. Why?
- Is basic of lean
- Push to understand value for customer
- Gives strengths and weaknesses of your company
- Start of teamwork and process thinking within your company.
 

 
Lean Manufacturing Tools for Beginners
Sabari, Analyst, India
Initially when your company wants to implement lean approach there is no one single tool to achieve it. There should be a series of steps taken at strategic, tactical as well as at operational level. Besides JIT, 5S, 6-sigma, answering of 5y's, agile operations, lean supply chain all can be considered as tools for achieving lean.
 

 
Lean Manufacturing Tools for Beginners
Paul Ryan, Other, Ireland
The company I am involved with are based in Ireland and are the manufacturers of food and drink. Lean has been implemented since 2008 and the company has since seen massive improvements. So far 4 tools are in place: SMED, 6S, Problem Solving and TPM. Do you think that more tools should be developed so further improvements can take place?
 

 
Lean Manufacturing Tools for Beginners
Eric Schmitz, Other, Belgium
With a sound basic of lean thinking - as you mention -, then Value Stream Mapping is surely possible and even absolutely necessary.
Maybe QFD is also a possibility combined with Hoshin?
 

 
Lean Manufacturing Tools for Beginners
Paul Ryan, Other, Ireland
Can you explain to me about Hoshin as I have never come across this tool before.
 

 
Lean Manufacturing Tools for Beginners
Eric Schmitz, Other, Belgium
Hoshin Kanri provides a step-by-step planning, implementation and review process for managed change or improvement. It works on the strategic level and on the daily management level.
If done properly, it will provide an organization where all people are familiar with the common objectives and where all improvement / projects... Are aligned with each other.
 

 
Lean Manufacturing Tools for Beginners
Paul Ryan, Other, Ireland
Is hoshin more or less defining long range and key objectives of the company. Does it involve top and middle managers across the board more so that all employees within the company.
 

 
Lean Manufacturing Tools for Beginners
Eric Schmitz, Other, Belgium
Hoshin is more police deployment and alignment. But it makes visble how customer needs, strategy, key objecives and also daily targets on a workplace are aligned with each other.
By doing this, top and middle managers are of course involved but also challenged to explain.
If done properly team spirit from top to bottom, from customer to supplier will be growing.
 

 
Lean Tools for Beginners
Jacques Ampe, Business Consultant, Belgium
Perhaps one reservation ... To what extent is the climate ripe for Lean to start... Personally, I think first a climate of 'change' should be created where a kind of 'urgency' is felt and where management is 100% behind this 'change'...
Then you can apply all Lean principles.
Note that Lean actually means that you involve your employees. If a culture exists in which employees are not involved, how can we then ever implement Lean?
 

   
 

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