TOP 26 LEAN TOOLS

Top Lean Manufacturing & Lean Management Tools

—Top Lean Tools are the systematic and scientific approaches for problem-
solving. Lean Tools are also used for identifying and eliminating waste from
the system or process. These tools are very important to implement Lean
Manufacturing culture ¡n the factory.
The list of top lean tools are:
1. Kaizen
2. jngle Piece Flow
3. Jidoka
4. Poka Yoke
5. Visual Management
6. Kanban
7. 8 Lean Wastes
8 Six Big Losses
9. Smart Goals
1O. Heijunka
11. Just in time
12. Takt time
13. Bottleneck Analysis
14. Andon
15. Gemba
16. Hoshin Kanri
17. OveraIl Equipment Effectiveness (OEE)
18. Cellular Manufacturing
19. Total Productive Maintenance (TPM).
2O. Total Quality Management (TQM)
21. Value Stream Study (VSM Study).
22. Single Minute Exchange of Dies (SMED)
23. Key Performance Indicators (KPIs)
24. 5S Methodology.
25. Standardize work
26. PDCA

1
 1) Kaizen or CONTINUOUS WORK

What is Kaizen?
Kaizen stands for “continuous improvement” or “small incremental
improvements” of all areas of a company.
- Kaizen word comes from the Japanese words kai which means “change or
improvement & zen” which means “for betterment.”
- The Lean tool Kaizen includes the involvement of all employees, from top
management to bottom personnel.

Benefits of Kaizen:
-It Improves processes by eliminating waste.
- Promotes personal growth of employees and the company
-Kaizen Improves quality, safety, cost structures, delivery, environments and it
improves customer service/satisfaction.

How to implement Kaizen at our workplace:

— The Kaizen method is generally implemented in 5 different steps:
-Identify an area having a problem.
-Analyze the data and method for the current process method.
- Testing and evaluating improvement possibility.
-Implement improvements.
-Analyze results and present them to top management for feedback.

2) Single Piece Flow

2
What is Single Piece Flow?
—Single Piece Flow is the sequence of a product or service through a process
that is the single unit is produced at a time.
—Single-Piece Flow is the opposite of batch production.
-In batch production, there is a large number of products are processed at
once.
—Single-Piece Flow is focused on the manufacturing of the product itself rather
than the waiting, transportation, and storage of the product.

Benefits of Single Piece Flow:

— Single Piece Flow detects defects earlier and more accurately.
—In Single Piece flow, we can get more flexibility for customization and meeting
customer demands.
—It reduces costs by eliminating various lean wastes.
- In Single Piece Flow we can easily predict the shipment timing.

3) Jidoka (Autonomation)

What is Jidoka (Autonomation)?

—- Jidoka means Autonomation
-Autonomation described as ‘intelligent automation” or “automation with a
human touch”
—- Jidoka (Autonomation) refers to partially automate manufacturing.
Partial automation is typically much less expensive than full automation.
—- Jidoka implements some supervisory functions rather than production
functions.
-In this concept, the machine or line is automatically stopped when defects are
detected.

Principles of Jidoka:
— The main principles of Jidoka are mentioned below.
- Detect the abnormality ¡n the operation or product.
— Stop the operation or product.
—Fix or correct the ¡mmediate condition of the process or product.
-Investigate the root cause and install a countermeasure in process or product.

Benefits of Jidoka(Autonomation):
-Jidoka helps employees fix problems as they occur.

3
—- It improves productivity.
-Jidoka reduces downtime and breakdowns.
—- It empowers employees and machines.

4) POKA-YOKE

What is Poka -Yoke?

—Poka-Yoke means Mistake Proofing or Error Prevention.
—Poka-Yoke prevents defects from being made or it highhghts a defect so that
it is not passed to the next operation.

Benefits of Poka-Yoke:
—Poka-Yoke saves time and money by preventing defects or being made
defective products.
—It is difficult to find all defects by inspection so we can use Poka-Yoke for
effective and efficient operation.
-Poka-Yoke prevents human error and it is a very important tool.

5) VISUAL MANAGEMENT

What is Visual Management?

—Visual Management is a communication technique that uses visual aids to
pass messages more effectively, more efficiently and very fast.
— Visual Management is the ability to manage everything in your factory or
areas by visually.

Benefits of Visual Management:

- Visual Management can display problems in a simpler way and very effective.

4
-Clearly indicates our targets and goals.
-Visual Management can increase the effectiveness of communication.
-Work instructions can be simplified by using the Visual Management Concept.

6) KANBAN

What is Kanban?
—Kanban means Signboard or Billboard.
—Kanban is a scheduling system for lean manufacturing and just-in-time
manufacturing (JIT).
-It takes ¡ts name from the cards that track production within a factory.
-Kanban controls the inventory level at any stage of production.

Benefits of Kanban:
— Kanban improves manufacturing efficiency
—One of the main benefits of kanban is to establish an upper limit to work in
process inventory to avoid overcapacity
—Kanban is an effective tool to support the running production system
—Kanban reduces wastes.

7 ) 8 LEAN WASTES

The 8 Wastes in Lean manufacturing are:

[1] Transportation waste: Transportation is related to all unnecessary
transportation activities within the organization.

[2] Inventory waste: Inventory waste is related to all finished goods and in-
process goods which are kept by us on because of the forecast and it is

5
nonmoving.

[3] Motion waste: Moving waste is related to people and equipment inefficiently
moving between tasks.

[4] Waiting waste: Waiting is how much time is consuming between your
production steps in ideal condition.

[5] Over Production waste: Over Production is that we are producing more
products than customers demand.

[6] Over Processing waste: We are doing more operations to finish good
products for that customer is not willing to pay.

[7] Defects waste: ‘The generation of defects in production is a total waste for
that we have to spend on rework or repair or scrap.

[8] Skills sets (non-utilized talent) waste: If we are not using our manpower
efficiently then that is a waste.

Benefits of eliminating 8 Lean Wastes:

—It increases productivity
-It creates a safer working environment
—Reduce downtime
-Improve efficiency and effectiveness

8) SIX BIG LOSSES

The six big losses are:

[l] Breakdowns or Unplanned Stops: It refers to mechanical failure and the
need for maintenance or stoppage due to an unplanned activity like manpower
are not available.

[2] Planned Stops or Setup/Adjustment: Machines are stopped due to planned

events, such as planned maintenance, safety inspections, or employee breaks
and Setup/Adjustment refers to changeover and machine warm-up.

[3] Small Stops or Idling: Small stops or Idling refers to machine stops for a
short duration of time to correct settings, unclog jams, and routine cleaning

6
activity.

[4] Speed or Slow Cycles: Speed or Slow Cycles are referred to machine runs
slower than designed, low efficiency of operator and machine wear down.

[5] Production Rejects or Defects: Production Rejects or Defects are defective

parts produced in the regular production, this is due to operator error or
incorrect settings.

[6] Startup Rejects or Startup losses: Startup Rejects or Startup losses are
defective parts produced at the time of machine startups or during the
operation or product changeovers

Benefits of analysis of Six Big Losses.

— Six Big Losses provides us with a framework for eliminating the most
common causes of waste in manufacturing.

9) SMART GOALS

What are SMART Goals?

—The SMART goal is the method to set the goal or target in an effective manner
The goals should be clearly defined and communicated.
— The acronym SMART stands for:
S - Specific
M - Measurable
A - Att amable or Achievable
R - Realistic or Results-Focused
T - Time-bound

10) HEIJUNKA

7
What is Heijunka?
—Heijunka means Leveling or Balancing.
—It is used to minimize batching and create a more efficient manufacturing
process.
—It is a type of production scheduling and it supports a predictable and steady
flow of small-batch manufacturing, instead of larger production processes used
for goods and components.

Example of Heijunka:
— Say a car manufacturer receives 1000 orders for cars every week. 200 on
Monday, loo on Tuesday, 100 on Wednesday, and 600 on Thursday. Instead of
manufacturing 1000 cars at the beginning of the week or the exact amount
needed each day, the company would produce exactly 200 cars per day. By
producing the same amount every day, the factory can optimize the
manufacturing operation for 200 cars and therefore create a more efficient
process.

Benefits of Heijunka:
-Heijunka (Leveling or Balancing) improves efficiency at all levels of the
manufacturing operation.
—It improves productivity and reduces the defects
—Heijunka reduces inventories, working capital costs, manpower, and
production lead time.

11) JUST-IN-TIME (JIT)

8
What is Just in Time?
It is focused on the production of customers requirement like when they want
it, how many quantities they want ¡t, and where they want it?

In this methodology, we produce the only customer’s ordered quantity instead

of creating a large stock of a product.

Benefits:
—It reduces unnecessary inventory.
—Minimize the storage need and ¡t gives companies flexibility in their
manufacturing operations.
— Save unnecessary expenses.

TaktTime(TJ )= Available Working Time per Day [Ta]/ Customer Demand per
Day [D]
What is Takt Time?
It is the maximum amount of time requires to produce the product and satisfy
the customers demand.
It is In other words: Net time available to work per unit of customers demand
or
Takt time (T) = Net time available to work (Ta)/Demand (customer demand) (D)

Where, T =Takt time, Ta = Net time available to work, e.g. [working 8 hours per
day]; D = Demand (customer demand), e.g. [units required is 1000 qty per day]

Example:
-if there are a total of 8hours(or480 minutes) In a shift(gross time)less 30
minutes lunch,20 minutes of tea breaks (2 x lo mins), lo minutes for a meeting
with team, then the net Available time to Work = 480-30-20-10=420 minutes.

- if customer demand were 840 units per day and one shift was being run, then
the line would be required to output at a minimum rate of two parts per minute
In order to satisfy the customers demand.

Benefits:
—it keeps track of production rates
— it helps us to set real-time targets for production and reduces unnecessary
wastes.
- We can achieve a consistent flow of production by using takt time
- We can eliminate the waste of overproduction by producing to meet actuai
customer demand.

12) BOTTLENECK ANALYSIS

9
What is Bottleneck?
—A Bottleneck means ‘constraint’.
—The bottleneck in operation is understood by the stage of operation that
takes the longest time in the whole operation
— The bottleneck refers to the slowest member of the whole operation or it can
determine the speed of the entire group.
—If one part of the whole operation is slow, then it can reduce the speed of the
whole operation.
-Also, it reduces the efficiency of the entire manufacturing process.

Benefits of Bottleneck Analysis:

-By removing bottleneck we can increase efficiency and profits.
—We can optimize the cycle time.
—Increase productivity and plant capacity.

13) ANDON

What is Andon?
—Andon is a visual signaling system for the shop floor that indicates
production status and alerts when assistance is needed
—Andon empowers operators to stop the production process if any abnormity
found in product or process.
—Usually, Andon uses a combination of lights and sounds to communicate any
problem, production status updates, highlight the issues, and any
achievements.

Benefits of Andon:
—Andon brings an immediate response to problems as they occur
—It empowers operators
—Andon keeps the shop floor person engaged with their tasks

10
 14) GEMBA

What is Gemba?
—Gemba is a Japanese word.
—Gemba means “The Real Place”.
- It means the actual place where the problem was found or an incident has
happened.
-As per Gemba theory, we must have to go at the Gemba for investigation of
any problem or incident.
—So problem solver’s or Cross function Team’s presence is necessary at
Gemba.
—The actual place may be referred: In manufacturing, it is a shop floor or it
can be a construction site, assembly line, any lab, office, etc....

Basic Principles of Gemba Walk:

— Basic Principles of Gemba Walk are mentioned below:
—Have a specific purpose of Gemba Walk.
—Be familiar with the area that you are visiting.
- Understand the overall process.
- Correctly understand what you are seeing.
— Know what to ask.

Benefits of Gemba:
—By Gemba walk, we can get easily knowledge of the plant’s productivity.
—Gemba gives a deep, thorough, and effective understanding of the
manufacturing process and problems by observation and discussions with
shop floor employees.

15) Hoshin Kanri

11
What is Hoshin Kanri?
-Hoshin Kanri is a Japanese Word it means Policy Deployment
— The word “hoshin’ means direction.
—And The word “kanri means administration.
— In Hoshin Kanri, the strategic goals of the company are communicated
throughout the company and then put into action with the help of middle
management.
—The top-down approach focus on steady communication for explaining
visions, developing and implementing policy from top to bottom management,
and receiving feedback from bottom to top management.

Benefits of Hoshin Kanri:

-The Hoshin Kanri practice helps us to ensure that all employees within an
organization are able to understand the organization’s vision.
—And all employees work toward a common goal of an organization.
—It eliminates the waste that comes from poor communication and an
unorganized direction.

16) Overall Equipment Effectiveness (OEE)

What is Overall Equipment Effectiveness (OEE)

-OEE is a method used to measure manufacturing efficiency by using
Performance Rate, Availability of Machine and Quality Rate.
—It measures the efficiency of Productivity in %.
—With O % means zero productivity it means an inefficient production.
—100% CEE means perfect production (produced only good parts, as fast as
possible, with no downtime).
—OEE is calculated with the formula,
—OEE= (Availability)*(Performance)*(Quality)

Benefits of OEE:
-Knowing OEE helps us to find inefficiencies in the production cycle.
-It helps us to set goals for improvement, and track the progress.
-OEE provides benchmark data for the new process setup.
-OEE helps to track progress in eliminating waste from a manufacturing
process.

17) Cellular Manufacturing

12
What is Cellular Manufacturing?
-Cellular Manufacturing ¡s creating process flow by dividing the full process
into small sub-processes or steps.
-This small sub-processes or steps are called cells.
— By combining these cells are called cellular manufacturing.
—In Cellular Manufacturing the similar products are produced in the same
cell.
—The product moves through the whole process without any stoppage or any
interruptions.
—Commonly the cells are arranged in a ‘U-shape design, this design allows a
supervisor to move less and have more watch over the entire process.

Benefits of Cellular Manufacturing:

-Cellular Manufacturing improves productivity and output
— Cellular Manufacturing reduces rejection and optimizes the floor space.
—Quick change over possible
-We can make a wide range of similar products in a single line.
—Reduce lead time.
—Enhance teamwork and communication between employees.

18) Total Productive Maintenance

What is Total Productive Maintenance?

—TPM is a well-defined system of maintaining and improving the production
system and quality systems between the processes, machines, employees,
equipment, and processes.
—TPM adds business value to an organization.
—Total Productive Maintenance (IEMÌ focuses on proactive and preventative
maintenance to maximize the operational time of equipment and reduce
equipment failure rate as much as possible in order to increase production

13
efficiency.
—TPM completely removes the difference between production and maintenance
by strong focuses on empowering operators to maintain their own equipment.

— The Eight Pillars of TPM:

1. Autonomous Maintenance
2. Focused Improvement
3. Planned Maintenance
4. Quality management
5. Early/equipment management
6. Education and Training
7. Administrative & office TPM
8. Safety Health Environment

Benefits of Total Productive Maintenance (TPM):

—TPM Reduces downtime and increases productivity
-It Improves Quality
—It creates a safer working environment
— TPM Enhance teamwork and communication between employees and
empower the operators

19)Total Quality Management (TQM)

What is Total Quality Management?

-Total Quality Management is a customer-oriented process and it focuses on
continuous improvement of Product, Process or Service of an organization.
—The goal of Total Quality Management (TQM) is to increase the quality at
every single step in an organization.

The Principles of Total Quality Management:

—Focus on customer
—Employee involvement
-Process-centered

14
-Integrated system
-A strategic and systematic approach
-Decision-making based on facts
—Communication
-Continuous improvement

Benefits of Total Quality Management:

-Total Quality Management (TQM) will increase the awareness of quality within
the organization.
-TQM establishes a quality-oriented culture within the organization
-TOM emphasis on teamwork.
-It will increase commitment towards continuous improvement within the
organization.

20) Value Stream Mapping

What is Value Stream Mapping?

—Value Stream Mapping is a method of analyzing the current state of a
process and designs the future state of the process and it focuses on the
opportunity for improvement by eliminating different wastes from processes.
—Value Stream Mapping includes the process, from the supplier end to reach
at the customer end.
-The process flow diagram is used to identify the waste and inefficiencies from
the process in Value Stream Mapping.

Main Three Parts of Value Stream Mapping are:

—Map Current State (Identify Waste)
—Design Future State
—Create a Transformation Plan

Some common data collection points for Value Stream Mapping are:
— The time is taken by one product or to pass one product from one station to
the next station
—Level of Inventory
—Number of operators
—A number of shifts worked

15
—Batch size
—Change over and delivery time
—Productivity etc...

Benefits of Value Stream Mapping:

— Value Stream Mapping addresses underlying issues.
—It helps to identify wastes and eliminate wastes.
-Value Stream Mapping helps to identify inefficiencies in the process.

21)Single-Minute Exchange of Dies (SMED)

What is the Single-Minute Exchange of Dies (SMED)?

-Single-Minute Exchange of Die (SMED) is a method for reducing setup or
change overtime in a manufacturing process to less than 10 minutes.
-The efficiency of the operation or process can improve by reducing the setup
or change over time in the factory.
—The concept of SMED was given by Frederick Taylor in 1911 and it was used
by Ford Motors in 1915.

Principles of the Single-Minute Exchange of Dies (SMED)?

—Identify changeover tasks.
—Analyze each task to determine the purpose.
— Determine low-cost solutions.
-Implement that solution to reduce the changeover time.

Benefits of Single-Minute Exchange of Dies (SMED):

—SMED improves efficiency
-SMED improves productivity
-It gives more flexibility to production.
-With the help of SMED, we can reduce inventory and enable a higher rate of
production.

22) Key Performance Indicators (KPI)

16
What are KPIs?
—KPIs are essential metrics set by the management in order to check the
success of lean manufacturing goals or performance of any process.
-Key Performance Indicators (KPI) are important for measuring efficiency,
waste, and productivity.

Examples of common manufacturing KPIs are:

—Speed
—Count
—Cost of Poor Quality
—Reject ratio
— Customer Satisfaction Index or rating
—MTBF, MTTR. etc.

Benefits of KPIs:
—it helps to improve efficiency and productivity
—It helps management to define the roles and responsibility of employees
—Create a vision, mission, and goals of an organization
-It helps to set objectives and targets

23)5S Methodology

What is 5S Methodology?
-5S Methodology. ¡s a system for organizing spaces so work can be performed
effectively & efficiently with safely.
— 5S Meaning:
[S1] Sein —p Sort
[S2] Seiton —. Set In Order

17
 [S3] Seiso —÷ Shine or Clean
[S4] Seiketsu —i Standardize
[S5] Shitsuke — Sustain

Benefits of 5S Methodology:
—Increase productivity through effectiveness
— Reduction i¡n delays
-Improved Quality
-Improve in Safety
-Set-up times reduced
-Morale & Motivation Increase
—Less stress for operators
—Safer work environment

24)Standardized Work

What is the Standardized Work?

—The standardized work is documented procedures for any process.
—It must be a live document so that it can be easily changed as per the
modification of the process.

Benefits of Standardized Work:

—Better documentation of current operation flow.
-Standardized Work helps to train the operator
—Improvement in productivity and profits.
-Reduces variation in the operation flow.
-It adds discipline towards a work.
—Standardized Work promotes problem-solving
—Standardize Work Increases teamwork across the organization.

25) PDCA cycle

18
What is the PDCA cycle?
-The PDCA Cy is the Plan-Do-Check-Act Cycle.
—PDCA is a well-defined problem solving method and continuous
improvement.
— The steps in the PDCA cycle are:
[1] Plan: Problem is identified and all employees work together to develop a
plan for making improvements or solving the identified problem.

[2] Do: The plan is implemented as per the defined solution by a cross-
functional team.

[3] Check: Check the implemented solution and also discuss further
improvements that can be possible or not?

[4] Act: The implemented solution is documented if it has successfully solved

the initial problem.

-- And If the solution is not satisfactory then again the cycle starts over at the
Plan phase for finding out other factors.

Benefits of the PDCA Cycle (Plan-Do-Check-Act Cycle):

— It helps to implement Kaizen and other continuous improvement activities.
—PDCA method improves the brainstorming skills of your team

26) SIX SIGMA

What is Six Sigma?

—Sigma (σ) is the Greek letter representing a statistical unit of measurement
that defines the standard deviation (SD) of a population.
-Six refers to the number of SD’s from the specialized limit to the mean.
—It measures the variability or spread of the data.
—6σ is a highly structured strategy.
—It is a comprehensive and flexible system for achieving, sustaining, and
maximizing business success.
— It is more about the culture than the tools and all the people who adopted
Quality in everything they do.

19
—It is people driving improvements based on facts and data and a detailed
roadmap of process improvement.
— It is an initiative that extends and strengthens quality and productivity
efforts.
—The old belief was high quality = high cost but new belief is high quality = low
cost.
— You can easily understand this concept by below analysis of cost vs quality

History of Six Sigma:

—Motorola has developed this concept in 1987.
-It is basically a bunch of various quality tools.
—One of the most important tools of this methodology is the Control Chart.
—Control Charts were developed way back in 1924 by quality guru Walter A.
Shewhart.
—Bill Smith of Motorola is considered to be the father of 6σ.
—Mikel Harry was also the Co-founder and he was sometimes referred to as
the father of 6σ.
—Motorola was the first company to receive the Malcolm Baldridge National
Quality Award in the year 1988.
— Looking at the success of 6σ at Motorola number of other companies, such
as General Electric, Dow Chemical, DuPont, Honeywell, Whirlpool adopted this
tool.

These are some of the early adopters.

—By adopting this method, many companies have improved their operation,
reduce their defects level, and to make their customers satisfied.
—Jack Welch of General Electric has made 6e more popular around the world.
-In General Electric, employee promotions were depending on whether the
employee had a specific 6σ belt or not.

Milestones:
—1986 6σ formulated by Bill Smith in Motorola.
-1988 Motorola becomes the first company to win the Malcolm Baldndge
National Quality Award.
— 1993 Allied Signal (Now Honeywell) adopted this methodology.
—1995 General Electric (GE) launched the 6o initiative.
— 1998 Honeywell adopted this method.

20
Benefits of Six Sigma Implementation:
—This Project improves the capability of their business.
-It increases the performance and decrease in variation.
—Decrease the defect generation.
-Improve profit of the organization.
—This project Improves employee morale and motivation.
—It improves in quality of products and customer satisfaction.
-Using 6σ Methodology, an organization can develop a strategy implement
proper action; or revenue and increase, cost reduction, and improvements.
—6σ Methodology helps management to create a vision of the organization.
—It helps to set the benchmark and after sustain and maintain the benchmark
further improve the benchmark this methodology helps us to continuously
improve the system.
— By 6σ methodology, organizations can set the goal and guide the team to
work towards achieving.
— It calculates the process performance using its own unit known as e unit
like our performance is 4σ, 5σ, etc...
—It is a robust methodology... problem solving and improvement.

What is the concept of Six Sigma?

It can be understood in three different approaches:

[01] Methodology Approach
DMAIC Methodology used for the Improvement Project.
— DMAIC is a structured problem-solving roadmap and tools.

[02] Philosophy Approach

— Reduce variation in your process and take customer-focused, data-driven
decisions.

[03] Metric Approach

3.4 Defects Per Million Opportunities.
DPMO allows you to take the complexity of the product/process into account.

— Rule of thumb is to consider at least three opportunities for a physical

part/component — one for form, one for fit, and one for function, in absence of
better considerations.

21
What are the 6 Sigma principles?
> Reduce the variation
> Maintain and improve the process at the specified mean
> Eliminating the defects and wastes
> Increase customer satisfaction
> Increase Productivity and Profitability

Why is it called Six Sigma?

— How many multiple standard deviations fit within each side of the
specification limit is the e level of the process.
— The concept of Mean, Central Tendency, and Standard Deviation is the
most important to understand the concept of Six_Sigma.
— 01. Mean: It is the arithmetic average of a process data set.
—02. Central tendency: It is the tendency of data to be around this mean or
average value.
— 03. Standard Deviation(o): Its a measure of variation.
—Higher the standard deviation means the value of data set to spread in a wide
range.
—Lower standard deviation means the values of data are near to the mean.
—If the value of e is lower then we can fix more e between process average and
specification limit so the higher e level is good.
—There are two types of specification limit: (a) Lower Specification Limit (LSL)
& (b) Upper Specification Limit (USL)
—Simply, we can say that the specification limit is the minimum and
maximum acceptable limits of the customer’s requirement.
— σ is the capability of the process, higher the e level means to lower the
defects and lower the e level means higher the defect.

22
23
24