Primary Tools of Lean Manufacturing

Following as:
 Value Stream Mapping
 Takt Time, The pace of production(Ex. Mfg.
one piece every 34 seconds)
 Cause-and- Effect
 Load Balancing
 Mistake Proofing

5S: According to Womack and Jones, there are

five
key lean principles: value, value stream, flow,
pull and perfection
What is 5S? Organize the work area:
• Sort(Eliminate that which is not needed)
• Straighten, Set In Order(Organize remaining
items)
• Shine, Sweep( Clean and inspect work area)
• Standardize( write standards for above)
• Sustain(regularly apply the standards)

How does 5S help?

Eliminates waste that results from a poorly
organized work area (waste time looking for a
tool)
 Lean Manufacturing Tools
• Lean has a very extensive collection of tools
and concepts. Surveying the most important of
these, understanding both what they are and
how they can help is an excellent way to get
started.

• One of the supporting pillars of the Toyota

Production System and hence Lean
Manufacturing, Jidoka is about built in quility
and encompasses ideas such as Automation
which is giving machines the “human touch” so
that they can stop when things are incorrect,
also Poka Yoka
• 5S is one of the basic building blocks of Lean
Manufacturing, one of the first lean tools that
you will start your implementation with and
one without which you cannot succeed.
• But what is 5S, what are the benefits of 5S, and
how do I set up a 5S program?
• 5S is not just for manufacturing processes, it
is as applicable in service and 5S office
implementations often give greater
improvements in lead time than those
conducted on your shop floor.
• With the addition of Safety as an additional “S”
we get 6S; 5S plus Safety.
 Process Mapping and Value Stream
Mapping
• Process mapping and Value stream using
ideas and techniques such as Value Stream
Mapping (VSM) or simple Flow charting or
spaghetti diagrams  are very powerful ways to
identify and highlight the wasteful steps in
your processes. This allows you to create
future state maps and create action plans to
simplify your work and drive improvements.
 Primary Tools- Process Mapping and
Value Stream Mapping
• The word MAP, it gives direction, distance and
route to reach from one place to another.
• Process map makes it faster (productive) to
achieve the task with minimum wastage.
• Process mapping the current process helps in
improving the process with a view to reduce
the cycle time and process cost. It also helps in
training of new employees.
• A process map is a visual presentation of the
process step by step. The process map serves
as a tool in lean manufacturing to understand
the current status of the process in steps.
• Conti….
The process map is used to identify the
boundaries of a process and where the
measurements are important.
Value stream mapping used in the case of
manufacturing is also a process map with
more emphasis on cycle time, inventory, etc.
The process map gives a pictorial view with
the sequence of all steps in the process.
In any organization there is waste in
processes. The focus of lean manufacturing to
eliminate waste from all activities. Keeping in
mind the customer need of faster delivery, low
price and good quility.
• Process mapping of the following activities is
essential:
1. Sales forecast
2. Material planning
3. Material handling
4. Production planning
5. Production process
6. Quality control
7. Supply chain
8. Stores
9. Despatch
 Advantages of Process Mapping
• It is most important tools in Lean
manufacturing for the following reasons:
1. It helps the lean the lean manufacturing team
to understand the current process and also
indentify the important opportunties.
2. The process map indentifies actual paths,
revealing areas of risk and potential solutions
by communicating process-realted ideas,
information, and data.
3. It makes the team to brain storm each of the
process steps also clearly identify the wastes
in the process.
4. The lean team can use the current process
map and future process map to clearly
quantify the improvement.
5. The process map can be used as a visual
training aid to train the personnel in the
improved process. The process map can
replace volumes of written material.
 Types of Process Maps
• The team responsible for preparing the process
map must agree to the starting point and
ending point of the process.
1. High- level process maps
2. Detailed process map

1) The cycle time between receipts of order to

delivery of the product may vary from product
to product.
The Product Manufacturing Types should identify
which of the product production cycle needs
detailed study.
2) This map is prepared after having a
brainstorming among the participants.
 How to Prepare a Process Map
• A process mapping team has to be formed
consisting of lean leader, process owner, and
associated departments.
The(PMT) should first attempt to prepare the
high-level process map.
Generally, the customer is looking for the
following three.
1. On time delivery
2. Good quality
3. Low price
• The team should brainstorm the processes
involved to achieve on time delivery and what
are to be mapped.
• Sales forecast
• Customer order processing
• Raw material planning
• Production planning
• Production process
• Dispatch process
 Value Stream Mapping
• It is tool used to visually indicate all actions
required to bring a product or service in logical
steps from start to finish.
The purpose of the value stream map is to
understand the value flow.
VSM graphically shows the following
1) Each process or activity
2) Inventory or queues between steps
3) Set up times, cycle time, etc.
4) Timeline for the whole value stream
5) Information flow from customer through the
production process
6) Changes needed to be implemented
A VSM helps in understanding how the product
flows from when the customer orders to the
dispatch of the product to the customer.

“STEPS TO BE FOLLOWED WHILE PREPARING

THE VSM”
1) Understand the current status and prepare
the current state map
Preparing the current state of the process
helps in the following
a) Communication
b) Understand the existing state
c) View the work from a process perspective
d) Understand the magnitude of the change
planned
e) Understand the tasks required to move from
the current processe.
f) Ensure problems are not repeated
g) Measure the new process on performance
base line.
Both the material flow and the information flow
should be mapped. Multiple maps may be
needed to understand the total process.
 The following steps are to be followed to
complete the current state map:
 Document customer information/ demand
 Complete a quick walk through to identify the
main processes.
 Map the basic production process
 Define the data to be collected
 Collect and map the data
 Document supplier information
 Establish information flow: how does each
process know what to make next?
 Indentify where material is being pushed
 Quantify production lead time versus processing
time
2) Collect the data
The following data have to be collected for all
the processes from the manufacturing area:
a) Cycle time: The time that elapses in seconds/
minutes, between one part coming off the
process and the next part coming in.
b) Changeover time: The time to switch from
producing one product type to another.
c) Available work time: The amount of work time
available / shift in each process.
d) Uptime: The amount of time the machine is
running(actual time).
e) Value added time: The time spent
transforming the product in a way that the
customer is willing to pay for.
f) Lead time: The time it takes for one piece to
travel through the entire value stream from
start to finish.
g) Costumer Demand: CD in quantity / month.
• 3) Arrange data in an information box
Lean Manufacturing Tools -5S