The lean manufacturing is the system undertaken by companies or organization to maximize their sale with less resource and with zero wastage. The ultimate goal is to adopt a good effective system for the development of the organization as well as its employees.
Lean manufacturing system was initially implemented by Japan. There was a significant change in the work ethics of the companies their resulting in increased in revenue generation. From there the idea was spread all over the world and now most of the companies have adopted this mechanism.
Lean manufacturing consultant doesn’t have fixed structure. It varies from organization to organization. But there are various tools which can be implemented in every organization for better result. Let us see.
The first and the basic tool is 5S tool. This tool helps the company to organize their workplace much efficiently. The main focus of the tool is to reduce waste and save time.
As the name suggest that this tool comprises of 5 different steps. The first phase is ‘Sor’t. In this we sort the equipment and eliminate those machines or materials which aren’t necessary. The second step is ‘Set in Order’ in which we organize the equipment as per requirement. The third step is ‘Shine’ in which all the equipment and the workplace should be cleaned. The fourth step is ‘Standardize’; record the visual for future instances and the last step is ‘Sustain’ i.e. to maintain the process for ever.
- Continuous flow
The next very important tool is the continuous flow or continuous improvement tool. This should be considered as an ethic rather than tool. However, this tool ensures continuous flow of raw materials to the production area and the final product to the market. It has various benefits such as it will reduce cost, time, and resources as well as decrease wastage.
Jidoka tool is very beneficial in manufacturing industries. Earlier the machines used to carry production process. Any defects or faults were only visible after the end product is quality checked. By this tool, we prepare machines to automatically stop production at time it detects fault and so the workers could immediately look the issue. This ensures no defected material in market.
One can say this tool is overall solution for every problem. Kaizen is system of continuous improvement in quality, quantity, work ethics and safety. It involves all the employees of the company to carry out each and every work. From manager to cleaning crew, everyone could come up with suggestions and all the tips are integrated to create a good process of eliminating waste and increase production.
Poor maintenance structure leads to several breakdowns of machine resulting decreased production, which is the biggest cause of loss to company. TPM emphasizes to create a proactive approach regarding maintenance work to maximize the operational time of equipment resulting in huge production. It creates a shared responsibility among the maintenance