Lean has actually a very extensive arsenal of tools and concepts. Surveying the most essential of these, understanding both what lock are and how they can help, is great way to get started.

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There are a lot of great ideas to check out in lean. For this reason where should you begin?

One method to begin is to survey the most essential lean tools, through a short description and also short explanation of exactly how each tool have the right to improve your manufacturing operations.

If a tool catches your interest or resonates with you in some method – check out it further to decide if it is miscellaneous to pursue now…or later. Many of this tools can be effectively used in isolation, which makes it much simpler to gain started. On the other hand, the benefits will certainly compound as an ext tools room used, together they carry out support and also reinforce each other.


25 Lean manufacturing Tools


What is 5S?

Organize the work-related area:

Sort: remove that i m sorry is not neededStraighten: organize staying itemsShine: clean and inspect job-related areaStandardize: write standards for aboveSustain: regularly use the standardsHow go 5S help?

Eliminates garbage that outcomes from a poorly organized job-related area (e.g., wasting time looking for a tool).


What is Andon?

Visual feedback system for the plant floor that shows production status, warns when assistance is needed, and also empowers operator to protect against the manufacturing process.

How walk Andon help?

Acts as a real-time interaction tool for the tree floor that brings prompt attention to difficulties as they happen – for this reason they deserve to be instantly addressed.

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Bottleneck Analysis

What is Bottleneck Analysis?Identify which component of the manufacturing procedure limits the in its entirety throughput and improve the performance of that part of the process.

How go Bottleneck analysis help?

Improves throughput by strengthening the weakest link in the production process.

Continuous Flow

What is continuous Flow?

Manufacturing where work-in-process smoothly operation through production with minimal (or no) buffers between steps the the manufacturing process.

How does constant Flow help?

Eliminates plenty of forms of rubbish (e.g., inventory, waiting time, and transport).

Gemba (The real Place)

What is Gemba?

A approach that reminds us to obtain out of our offices and also spend time ~ above the plant floor – the ar where real action occurs.

How does Gemba help?

Promotes a deep and also thorough understanding of real-world manufacturing worries – by first-hand observation and by talking with plant floor employees.

Heijunka (Level Scheduling)

What is Heijunka?

A kind of manufacturing scheduling that purposely manufactures in much smaller batches by sequencing (mixing) product variants within the same process.

How does Heijunka help?

Reduces lead times (since every product or different is manufactured an ext frequently) and inventory (since batches are smaller).

Hoshin Kanri (Policy Deployment)

What is Hoshin Kanri?

Align the purposes of the agency (Strategy), v the plan of middle administration (Tactics) and also the work performed top top the plant floor (Action).

How does Hoshin Kanri help?

Ensures that development towards strategic objectives is consistent and thorough – eliminating the waste that comes from bad communication and also inconsistent direction.

Jidoka (Autonomation)

What is Jidoka?

Design tools to partly automate the manufacturing procedure (partial automation is typically much less expensive than complete automation) and to automatically stop once defects space detected.

How go Jidoka help?

After Jidoka, workers can generally monitor multiple train station (reducing labor costs) and many quality problems can be detected immediately (improving quality).

Just-In-Time (JIT)

What is Just-In-Time?

Pull parts through production based on customer need instead the pushing parts through production based upon projected demand. Depends on many lean tools, such as continuous Flow, Heijunka, Kanban, standardized Work, and also Takt Time.

How does Just-In-Time help?

Highly reliable in to reduce inventory levels. Boosts cash flow and reduces an are requirements.

Kaizen (Continuous Improvement)

What is Kaizen?

A strategy wherein employees work together proactively to attain regular, incremental improvements in the manufacturing process.

How walk Kaizen help?

Combines the cumulative talents of a company to develop an engine for continually eliminating waste from production processes.

Kanban (Pull System)

What is Kanban?

A an approach of regulation the flow of items both within the factory and also with outside suppliers and also customers. Based on automatic replenishment with signal cards that show when more goods are needed.

How walk Kanban help?

Eliminates waste native inventory and also overproduction. Can remove the need for physics inventories, rather relying on signal cards to show when much more goods need to be ordered.

KPIs (Key performance Indicators)

What are KPIs?

Metrics designed to track and also encourage progress towards vital goals that the organization. Strongly advocated KPIs have the right to be extremely powerful drivers of habits – so that is important to carefully choose KPIs that will drive desired behavior.

How execute KPIs help?

The ideal manufacturing KPIs:

Are aligned v top-level strategic goals (thus helping to achieve those goals)Are reliable at exposing and quantifying rubbish (OEE is a good example)Are readily influenced by plant floor employees (so they deserve to drive results)

Muda (Waste)

What is Muda?

Anything in the manufacturing process that walk not add value from the customer’s perspective.

How go Muda help?

It doesn’t. Muda way ‘waste’. The removed of muda (waste) is the primary emphasis of skinny manufacturing.

Overall Equipment performance (OEE)

What is as whole Equipment Effectiveness?

Framework because that measuring efficiency loss for a provided manufacturing process. Three categories the loss room tracked:

Availability (e.g., downtime)Performance (e.g., slow cycles)Quality (e.g., rejects)How does all at once Equipment performance help?

Provides a benchmark/baseline and also a method to track progression in eliminating waste native a production process. 100% OEE method perfect manufacturing (manufacturing only good parts, as rapid as possible, with no downtime).

PDCA (Plan, Do, Check, Act)

What is PDCA?

An repeat methodology because that implementing improvements:

Plan: create plan and also expected resultsDo: implement planCheck: verify expected outcomes achievedAct: review and also assess; do it againHow does PDCA help?

Applies a scientific strategy to make improvements:

Plan: develop a hypothesisDo: run experimentCheck: advice resultsAct: refine your experiment; shot again

Poka-Yoke (Error Proofing)

What is Poka-Yoke?

Design error detection and also prevention into production procedures with the score of achieving zero defects.

How does Poka-Yoke help?

It is daunting (and expensive) to discover all defects with inspection, and correcting defects commonly gets significantly much more expensive at each stage of production.

Root cause Analysis

What is Root cause Analysis?

A trouble solving methodology that focuses on resolving the underlying problem instead of using quick fixes that only treat immediate symptoms that the problem. A common strategy is come ask why five times – every time relocating a step closer to finding out the true basic problem.

How does source Cause analysis help?

Helps to ensure that a problem is truly got rid of by applying corrective action to the “root cause” the the problem.

Single-Minute Exchange of dice (SMED)

What is Single-Minute Exchange the Die?

Reduce setup (changeover) time to less than 10 minutes. Approaches include:

Convert setup measures to be external (performed if the procedure is running)Simplify internal setup (e.g., change bolts with knobs and levers)Eliminate non-essential operationsCreate Standardized job-related instructionsHow go Single-Minute Exchange of die help?

Enables production in smaller sized lots, reduces inventory, and also improves client responsiveness.

Six big Losses

What is Six big Losses?

Six category of performance loss the are almost universally proficient in manufacturing:

BreakdownsSetup/AdjustmentsSmall StopsReduced SpeedStartup RejectsProduction RejectsHow does Six big Losses help?

Provides a structure for attacking the many common reasons of rubbish in manufacturing.


What are SMART Goals?

Goals the are: Specific, Measurable, Attainable, Relevant, and also Time-Specific.

How carry out SMART goals help?

Helps come ensure that purposes are effective.

Standardized Work

What is standardized Work?

Documented measures for manufacturing that capture best practices (including the moment to finish each task). Should be “living” documentation that is simple to change.

How walk Standardized work help?

Eliminates rubbish by consistently applying best practices. Forms a baseline for future innovation activities.

Takt Time

What is Takt Time?

The pace of production (e.g., manufacturing one piece every 34 seconds) that aligns manufacturing with client demand. Calculated as Planned manufacturing Time / customer Demand.

How go Takt Time help?

Provides a simple, consistent and also intuitive method of pacing production. Is quickly extended to provide an efficiency goal for the plant floor (Actual pieces / Target Pieces).

Total productive Maintenance (TPM)

What is total Productive Maintenance?

A holistic technique to maintain that focuses on proactive and also preventative maintain to maximize the work time that equipment. TPM blurs the difference between maintenance and production by place a strong emphasis on empowering operator to aid maintain their equipment.

How does full Productive maintenance help?

Creates a common responsibility for devices that motivates greater authorized by plant floor workers. In the right environment this deserve to be really effective in improving productivity (increasing increase time, reducing bicycle times, and eliminating defects).

Value currently Mapping

What is worth Stream Mapping?

A tool offered to visually map the flow of production. Shows the current and also future state of procedures in a means that highlights avenues for improvement.

How does worth Stream Mapping help?

Exposes waste in the existing processes and provides a roadmap for development through the future state.

Visual Factory

What is visual Factory?

Visual indicators, displays and controls provided throughout manufacturing plants to improve communication of information.

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How go Visual factory help?

Makes the state and condition of production processes easily obtainable and an extremely clear – to everyone.