5s method - arranged workplace
Smed method - quick changes
KAIZEN - continuous improvement
SFM - Morning meetings in production
Lean methods and principles of lean manufacturing to reduce losses in the business process.
What does the term Lean mean, which we translated into Slovenian as “slenderness”?
These are methods where we are constantly looking for losses in processes and trying to reduce or even eliminate them. Losing is an Easter task that does not add value to our customer and he is not willing to pay for it. It can be invested time, energy, resources, material, space or anything else that represents value. In short, this could also be described as clj to produce more while reducing input.
Slimness is not a one-time change, it is a constant process. There is always room for improvement.
The theory states five basic principles of slimness:
- Value (first it is necessary to determine the value of the product for the customer, what are the maximum costs that the customer is still willing to pay)
- Value flow (we review the entire path of the product, from development to customer use, each process is reviewed, what added value it brings us, everything that does not bring added value to the product, we try to remove)
- Flow (each process should be synchronized with others, no time gaps)
- Pull (nothing is done until an order comes from an internal or external customer, which shortens delivery time and increases flexibility)
- Perfection (the product should be perfect on the first try, in case of problems and poor quality, and let’s delve into the causes, which we eliminate on an ongoing basis)
Lean production tools (Lean methods) are not limited to industry, but are used in many fields. The basic plan is to study and eliminate losses in all parts of the value stream. To reduce costs, create capital, increase sales and stay competitive in a growing global market.
Loss removal is a process that requires an overview of all independent segments of the entire company. From input materials to distribution and sale of finished products. It is important to focus on the process as well as people, suppliers and customers. The main goal of lean manufacturing is to coordinate and improve the processes of creating a good end product or service along the value stream.
Lean manufacturing methods try to analyze in detail all the steps needed to make a good product or service. Everything from idea to production, from order to delivery. From raw material to delivered quality finished product. However, for the full implementation of this approach, it is necessary to involve all the company’s services that are in any connection with each step of the final product.
To help you understand the concept of lean manufacturing and the methods we use to optimize business processes, we will explain some basic concepts below.
Toyota has developed its own production system (Lean methods) to eliminate three main barriers to production: “muda” (losses), “muri” (overload) and “mura” (imbalance).
Overload losses include overwork of workers, which manifests itself as fatigue, a bad atmosphere in the company. Increased errors, as well as incorrect line planning and too high machine clock time, too short tool change times, etc. We understand as an imbalance the losses caused by the control of the production, when it did not sufficiently coordinate the capacity with each other.
Muda is a direct barrier to material flow. As shown in Chapter 3.2, there are 7 types of production losses that together lead to lower productivity and longer flow times. Just removing the mude from the process does not work, as all three components are closely related to each other, so the reason for the formation of one component often has to do with the other two.
The support and motivation of the company’s management is crucial at this starting point. Lean or lean production, efficiency, productivity, reliability, availability, performance, management, process optimization, with methods: TPM , 5S , Kaizen , SMED , SFM . etc., are indispensable elements of any organization that wants to successfully compete in the global market.
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It should be emphasized that 100% elimination of these three barriers is not possible, but the goal of lean manufacturing is to minimize barriers in the process.