When we talk about Lean Manufacturing<\/a>, we are referring to a concept rich in nuances that can be implemented through a wide variety of methods and tools.<\/p>\n Throughout several articles on our blog, we have extensively covered various aspects of the Lean philosophy<\/a> in industrial plants. Therefore, we believe this is an excellent opportunity to bring together in a single text the main tools for applying Lean Manufacturing principles in an industrial facility.<\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” min_height=”30px” custom_margin=”8px||44px|||” global_colors_info=”{}”] We have identified a total of 8 main tools, which we will describe in more detail below.<\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” min_height=”117px” custom_margin=”-43px|||||” global_colors_info=”{}”] Order and cleanliness are the key to this Lean tool, which, as its name suggests, is based on 5 principles aimed at eliminating anything unnecessary within production processes:<\/p>\n <\/p>\n Its main objective is to minimize equipment breakdowns and, consequently, the costs associated with them, both from the actual repair and from the production downtime while everything returns to normal.<\/p>\n In Total Productive Maintenance, the contribution of the 5S is very helpful, as the organization and cleanliness of the equipment are essential to preventing breakdowns.<\/p>\n TPM is based on three fundamental pillars:<\/p>\n Within TPM, a key metric known as Overall Equipment Effectiveness<\/em> (OEE) plays a special role. This measures the degree of utilization of equipment in a factory, and its calculation depends on availability, performance, and quality<\/a>. <\/p>\n According to a study conducted by specialists from Universitas Brawijaya Malang<\/em><\/a>, in plants that use Lean Manufacturing tools, their OEE is around 85%.<\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” custom_margin=”7px|||||” custom_padding=”0px|||||” global_colors_info=”{}”] This technique is based on pull production systems, where manufacturing operates based on demand, reducing inventory <\/a>and its associated costs, and adhering to the just-in-time principle<\/a>.<\/p>\n Only the quantities required by the customer are produced, and at each stage, those responsible for it must:<\/p>\n With this methodology, the overall manufacturing process flows without stoppages or bottlenecks that hinder it.<\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ global_colors_info=”{}”] Housekeeping is closely related to 5S and the planning of audits that evaluate aspects related to this tool within Lean Manufacturing.<\/p>\n Within Housekeeping, a series of very interesting options are available in the corresponding Polaris module. Among these possibilities, we have the option to work in real-time with corrective actions and to use a Kanban board as reinforcement. <\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”] And since we’re talking about Kanban, let’s refresh the basics of this Lean tool. It is based on two key elements: <\/p>\n <\/p>\n Lean Manufacturing is closely related to the automatic execution of actions within production.<\/p>\n These automations go far beyond the robots that often come to mind when thinking of a modern production line.<\/p>\n Automation also includes actions such as the intelligent assignment of tasks <\/a>based on variables like skills, location<\/a>, or workload, as well as the automatic collection and processing of variables of interest for aspects like quality, equipment maintenance, or production optimization.<\/p>[\/et_pb_text][et_pb_image src=”https:\/\/puntazo.sixphere.com\/wp-content\/uploads\/2020\/03\/Procesos-Lean-Manufacturing.jpg” alt=”Lean Manufacturing processes” _builder_version=”4.16″ global_colors_info=”{}”][\/et_pb_image][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”] Poka Yoke<\/a> is a tool designed to minimize human errors that may occur within a factory. Depending on the purpose for which they are established, we can identify different types of Poka Yoke tools: <\/p>\n <\/p>\n Through VSM (Value Stream Mapping), we obtain a visual representation of all the processes and the flows of materials and information that take place in the plant.<\/p>\n With this visualization on a map of the critical and highest-value points in the factory, we can also identify the main sources of problems and losses in time, resources, or materials.<\/p>\n But, while the problems are clearly visualized, VSM also helps to identify potential solutions to these barriers to efficiency and productivity<\/a>.<\/p>\nMain Lean Manufacturing tools<\/h2>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” min_height=”61px” custom_margin=”-24px|||||” global_colors_info=”{}”]
\n
1.- 5S<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
\n
2.- Total Productive Maintenance (TPM)<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
\n
3.- Continuous Flow or One-Piece Flow<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
\n
4.- Housekeeping<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
5.- Kanban<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
\n
6.- Task Automation<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
7.- Poka Yoke<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
\n
8.- Value Stream Mapping (VSM)<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]