Overview Lean Tools, Techniques & House of Lean

Resource: Oveview Tools, Techniques & House of Lean

Tools and Techniques of Lean Manufacturing
1. Basic Lean 6. Visual status display
– Continuous improvement(Kaizen)– 5S (Andon system)– Value stream mapping
– Visual management
2. Streamlined flow
3. Single piece flow
4. Standardized work
5. Line balancing
6. Visual status display
7. Error proofing (Poka ‐yoke)
8 Total productive maintenance
9. Quick changeover (Single minute change of dies SMED)
10. Kanban (Pull system)
11. Cellular/Flow manufacturing
12. Self directed work teams
Traditional House of Lean
Under the lean manufacturing system, seven wastes are identified: overproduction,
inventory, motion, defects, over-processing, waiting, and transport.

Identifying waste
Types of waste
Daniel T. Jones (1995) identifies seven commonly accepted types of waste. These terms are
updated from Toyota's operating model "The Toyota Way" (Toyota Production System, TPS)
original nomenclature (muda)

1. Faster-than-necessary pace: creating too much of a good or service that

damages production flow, quality, and productivity. Previously referred to as
overproduction, and leads to storage and lead time waste.
2. Waiting: any time goods are not being transported or worked on.
3. Conveyance: the process by which goods are moved around. Previously
referred to as transport, and includes double-handling and excessive movement.
4. Processing: an overly complex solution for a simple procedure. Previously
referred to as inappropriate processing, and includes unsafe production. This
typically leads to poor layout and communication, and unnecessary motion.
5. Excess Stock: an overabundance of inventory which results in greater lead
times, increased difficulty identifying problems, and significant storage costs.
Previously referred to as unnecessary inventory.
6. Unnecessary motion: ergonomic waste that requires employees to use excess
energy such as picking up objects, bending, or stretching. Previously referred to
as unnecessary movements, and usually avoidable.
7. Correction of mistakes: any cost associated with defects or the resources
required to correct them.
Waste removal operations
Monden (1994) identifies three types of operations

1. Non-value adding operations (NVA): actions that should be eliminated, such

as waiting.
2. Necessary but non-value adding (NNVA): actions that are wasteful but
necessary under current operating procedures.
3. Value-adding (VA): conversion or processing of raw materials via manual labor.

NNVA activities may also be referred to as "sustaining non-value adding", i.e. they have to be
done, or they are necessary to sustain the business but do not contribute to customer
requirements