Lean Manufacturing Techniques

“Ever changing globalized environment has been posing challenges to the organisations. Lean Manufacturing is a set of following
techniques which will help in reducing cost by eliminating wastes and increase productivity. The list of LM techniques and a brief write up is given hereunder.

1. 5S System:
The 5S System is a workplace management which helps in getting the “unwanted” out of the work area and set of procedures to keep it that way. 5S stands for SEIRI, SEITON, SEISO, SEIKETSU AND SHITSUKE ( Sort (wanted and unwanted), Set in Order (Place for everything and everything in its place – PEEP Shine, Standardize and Sustain – Discipline)

2. Visual Control:
Visual controls such as charts, signal, light, etc. Lane marking floor. Safety instructions Poke -Yoke
instructions,One point lesson, etc can be displayed all over the workplace. Most of it would be cover when we implement 5S System.

3. Standard Operating Procedures (SOPs):
All verbal instructions should be converted to SOPs to remove dependency on skilled personnel in achieving required product quality level, consistency, effectiveness and efficiency.

4. Just in Time (JIT):
It is a Japanese manufacturing philosophy to make the right product in right quantity at the right time. This results in zero inventory and shortest possible cycle time.

5. KANBAN System:
In this, components are pulled by the next internal customer and this reduces the inventory.

6. Cellular Layout :
In this improved manufacturing system, family wise component completion is aimed at within the smaller self contained cell, which is a part of a big–big factory, as compared to operation-wise completion in traditional functioning layout.

7. Value Stream Mapping:
It covers all activities, both value added and non-value added, and helps in arriving at the best layout of all resources required for making the product.

8. Poka Yoke or Mistake Proofing:
It is again a Japanese technique used to prevent errors occurring at their source of origin and it finally leads to achieving ZERO Defect.

9. Single Minute Exchange of Dies or Quick Changeover (SMED): 
Applying ingenious methods,, set up time is minimized and brought to less than ten minutes; thereby smaller batches as required by the customer can be taken up for manufacturing.

10. Total Productive Maintenance (TPM):
TPM involves operators, maintenance staff and management working together to improve overall operation of any equipment. Operators, first identify noisy or vibrating motors, oil or air leaks, can be
trained to make simple repairs to prevent major and costly breakdowns.

11. Kaizen:
It is an intense management, which will result in immediate change and bottom line improvement.