Lean manufacturing is an essential methodology for achieving optimal productive processes. Its principles guide product quality care, resource saving, and timely maintenance of machinery and equipment involved in the production chain. This methodology also has tools that facilitate the work, control, and monitoring of operations.
In this text, we tell you about 5 lean manufacturing tools you should know.
To begin, lean manufacturing is a methodology widely used in the industrial sector. But what does it consist of? Roughly speaking, when applied, it seeks to maximize the value of products by optimizing production processes, aiming to minimize the loss or generation of waste as much as possible.
Originating in the Toyota production system, this methodology deals with boosting the flow of materials and minimizing the costs associated with excess inventory, waiting times, and defects in the resulting products.
All in all, lean manufacturing seeks the continuous improvement of production systems to, on the one hand, contribute to the well-being of operators and specialists and, on the other hand, create value with the least amount of resources. Hence, it is a methodology that requires a comprehensive approach oriented not only towards adaptation to new technologies but also towards innovation.
The lean manufacturing methodology has principles that are key to improving both business strategy and productive efficiency. What are they? These keys are detailed below:
However, to fully understand this, it is necessary to understand that lean manufacturing also has certain guidelines, namely:
In the lean manufacturing methodology, there are various tools that help optimize processes and eliminate waste. Below are described some of the most important lean manufacturing tools.
This is a tool that seeks to maximize the efficiency of a company's physical assets, such as machinery and other instruments used in production. It is a preventive approach that uses at least eight essential aspects to achieve optimal equipment operation, namely:
The manufacturing of one piece at a time through a systematized and uninterrupted process is known as continuous flow or, in English, one piece flow. In the lean manufacturing methodology, this tool is fundamental for reducing waiting times, as well as managing excess inventory or stock. In addition to this, continuous flow increases efficiency, reduces downtime, waiting, and, especially, waste derived from such circumstances.
In lean manufacturing, what is currently a mandatory method in all industries cannot be missing: automation. This refers to the incorporation of technologies, digital solutions, and automated systems to perform repetitive, precise, and complex tasks with greater accuracy compared to human labor. In this sense, automation involves reducing errors, accelerating processes, improving control, and collecting data on operations. With this, the just in time principle is met.
Poka-Yoke is a method created by Toyota to prevent or minimize errors in the production chain and even storage. How is it applied? It starts with the analysis and understanding of the task; once this is completed, a strategy or procedure is created to optimize the process, as the goal is to avoid defects or errors. At all times, the objective is to guarantee product quality.
The value stream map or, in English, value stream mapping is a tool intended to observe and analyze the flows of materials throughout the production process; in addition, information is collected that makes it possible to identify and eliminate activities that detract from value in manufacturing. With the created flow map, companies can identify blockages or bottlenecks, inactivity, waiting times, and other problems. Consequently, available resources and time are optimized.
These are the advantages and disadvantages of applying the 5 lean manufacturing tools mentioned above.
The use of lean manufacturing tools offers numerous advantages. Among them, those already pointed out: reduction of defects, improved efficiency, and optimization of costs associated with the production process. Indeed, these tools allow companies to adapt quickly to changes in demand and reduce excess inventory, which translates into lower operating costs.
However, the implementation of these tools also presents certain drawbacks. It requires a significant initial investment in training and in adapting existing processes. Furthermore, integrating these tools into traditional production systems can be complex, which may generate resistance to change. Despite these challenges, the long-term benefits of adopting lean manufacturing usually outweigh the initial difficulties.
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