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Top 25 Lean Tools PDF
Top 25 Lean Tools PDF
©2010 Vorne Industries Inc., Itasca, IL USA ● 877-767-LEAN ● www.vorne.com ● www.leanproduction.com ● www.oee.com
Lean Tool What Is It? How Does It Help?
Overall Framework for measuring productivity loss for a Provides a benchmark/baseline and a means to track
Equipment given manufacturing process. Three categories of progress in eliminating waste from a manufacturing
Effectiveness loss are tracked: process. 100% OEE means perfect production
(OEE) • Availability (e.g. down time) (manufacturing only good parts, as fast as possible, with
• Performance (e.g. slow cycles) no downtime).
• Quality (e.g. rejects)
PDCA (Plan, Iterative methodology for implementing Applies a scientific approach to making improvements:
Do, Check, improvements:
Act) • Plan (establish plan and expected results) • Plan (develop a hypothesis)
• Do (implement plan) • Do (run experiment)
• Check (verify expected results achieved) • Check (evaluate results)
• Act (review and assess; do it again) • Act (refine your experiment; try again)
Poka-Yoke Design error detection and prevention into production It is difficult (and expensive) to find all defects through
(Error processes with the goal of achieving zero defects. inspection, and correcting defects typically gets
Proofing) significantly more expensive at each stage of production.
Root Cause A problem solving methodology that focuses on Helps to ensure that a problem is truly eliminated by
Analysis resolving the underlying problem instead of applying applying corrective action to the “root cause” of the
quick fixes that only treat immediate symptoms of the problem.
problem. A common approach is to ask why five
times – each time moving a step closer to
discovering the true underlying problem.
Single Minute Reduce setup (changeover) time to less than 10 Enables manufacturing in smaller lots, reduces inventory,
Exchange of minutes. Techniques include: and improves customer responsiveness.
Die (SMED) • Convert setup steps to be external (performed
while the process is running)
• Simplify internal setup (e.g. replace bolts with
knobs and levers)
• Eliminate non-essential operations
• Create standardized work instructions
Six Big Six categories of productivity loss that are almost Provides a framework for attacking the most common
Losses universally experienced in manufacturing: causes of waste in manufacturing.
• Breakdowns
• Setup/Adjustments
• Small Stops
• Reduced Speed
• Startup Rejects
• Production Rejects
SMART Goals Goals that are: Specific, Measurable, Attainable, Helps to ensure that goals are effective.
Relevant, and Time-Specific.
Standardized Documented procedures for manufacturing that Eliminates waste by consistently applying best practices.
Work capture best practices (including the time to complete Forms a baseline for future improvement activities.
each task). Must be “living” documentation that is
easy to change.
Takt Time The pace of production (e.g. manufacturing one Provides a simple, consistent and intuitive method of
piece every 34 seconds) that aligns production with pacing production. Is easily extended to provide an
customer demand. Calculated as Planned Production efficiency goal for the plant floor (Actual Pieces / Target
Time / Customer Demand. Pieces).
Total A holistic approach to maintenance that focuses on Creates a shared responsibility for equipment that
Productive proactive and preventative maintenance to maximize encourages greater involvement by plant floor workers. In
Maintenance the operational time of equipment. TPM blurs the the right environment this can be very effective in
(TPM) distinction between maintenance and production by improving productivity (increasing up time, reducing cycle
placing a strong emphasis on empowering operators times, and eliminating defects).
to help maintain their equipment.
Value Stream A tool used to visually map the flow of production. Exposes waste in the current processes and provides a
Mapping Shows the current and future state of processes in a roadmap for improvement through the future state.
way that highlights opportunities for improvement.
Visual Factory Visual indicators, displays and controls used Makes the state and condition of manufacturing
throughout manufacturing plants to improve processes easily accessible and very clear – to everyone.
communication of information.
©2010 Vorne Industries Inc., Itasca, IL USA ● 877-767-LEAN ● www.vorne.com ● www.leanproduction.com ● www.oee.com