Lean Concepts
Lean Concepts
Lean Concepts
Lean Manufacturing Terms and Concepts
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A pull system is a production or service process which is designed to deliver goods or services as they are required by the customer or, within the production process, when required by the next step. This type of system can also be called a build to order production/inventory sytem
The pull system is usually implemented with the aid of a kanban card system . This kanban card system is used to provide a sign or signal by the next step in the process or downstream operation that it requires inputs in forms of raw materials or WIP from the previous or upstream operation/ work station. This ensures that parts or materials move only when required and in the manner and configuration as required.
The pull system is also called a JIT system because it operates Just in time in delivering finish goods, materials or WIP when it is needed instead of just to accumulate inventory.
A lean office is a term that refers to an office, administration or back office support operation which applies and makes use of the lean principles or lean manufacturing ideology to achieve smooth work processes and enhance the flow of information to achieve more efficient outcomes and productivity.
Error proofing entails minimizing the opportunities the operator or human interaction into the process has of making a mistake that can cause any type of waste , downtime or quality issues. Poka yoke are error proofing controls or engineering solutions to error proof work tasks, processes and functions in order to avoid costly mistakes.
Error proofing can sometimes lead to loss of skills and operator focus on key items as error proofing is commonly achieved by automation and standardization of tasks. These two things are preferred solutions to avoid problems and will most definitely do so, but they can take control and opportunity to rectify an issue away from the operator and when the situation does get out of control the operators will almost certainly require engineering or technical support.
Items like checklists are very good error proofing measures when they are done properly and not just as a tick and flick exercise. Continuous training and upskilling with OPL’s and review of SOP’s can also help in avoiding operator errors. Most errors are made when operators are new to the plant or process, become complacent and forgetful of skills which are not used as often.
A lean audit is intended to give a snapshot of the pace or progress of the implementation of lean manufacturing and continuous improvement culture and kaizen initiatives in an organization or specific site. It is usually gauged by the level of implementation and improvement observed in a number of key lean manufacturing components which include:
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