Spaghetti Plot – Visualize the process inefficiencies caused by layout

Spaghetti Plot is a method of viewing observations to visualize possible flows through systems. Flows depicted in this way appear like noodles, hence the coining of this term Spaghetti Plot. This method of statistics was first used to track routing through factories. Visualizing flow in this way can cut inefficiency within the flow of a […]

Single-Minute Exchange of Die (SMED)

Single-Minute Exchange of Die (SMED) is one of the many lean production methods for reducing waste in a manufacturing process. It provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product. This rapid changeover is key to reducing production lot sizes and thereby improving […]

Seven wastes in Service industry

The original seven wastes (Muda (Japanese term)) were defined by Taiichi Ohno, the father of the Toyota Production System. These wastes have been often redefined to better fit new organisations, industries, or external pressures. The effect of the waste is visible in a manufacturing industry. Adopting the Seven wastes in Service industry  is really difficult as […]

Identification of Six Sigma Projects – Idea Generation

We had some guidance on the six Sigma Projects. Now let us focus on identification of Six Sigma Projects. Six Sigma is accomplished one project at a time. Identification of Six Sigma Projects shall aim at breakthrough Improvements and not simple goals. The billion of dollars saved by companies around the world is the cumulative […]

What is Value Stream Mapping (VSM)

Value Stream Mapping (VSM) is a Lean tool, to visualize the various steps and their contribution to the overall process. Value When a product or service has been perceived or appraised to fulfill a need or desire–as defined by the customer–the product or service may be said to have value or worth. Components of value may […]

What is Rapid Improvement Event (RIE)

Rapid Improvement Event (RIE) is a 4-5 day process utilizing a team based methodology to apply the lean tools for seeing waste and making immediate improvement. The focus in a Rapid Improvement event is to work on the set up time or the Changeover time. Set-up Time Work required to change over a machine or process […]

De-bottlenecking process and improving throughput

De-bottlenecking is  one of the very good lean tools focus on reducing cycle time and improving throughput. One of the important toll used is to study the bottlenecks in the system and improving throughput. A systemic approach is taken in studying, analyzing and acting on the bottlencks. A similar approach is taken in the theory of […]

Cellularization or Cellular Manufacturing

In lean Manufacturing, Cellurization or Cellular Manufacturing is used to great affect. These are the Quality control tools used for cycle time reduction and set up time reduction. Cellular Manufacturing An approach in which manufacturing work centers (cells) have the total capabilities needed to produce an item or group of similar items; contrasts to setting […]

What is Autonomation

Autonomation: Described as “intelligent automation” or “automation with a human touch.” If an abnormal situation arises the machine stops and the worker will stop the production line. Prevents the production of defective products, eliminates overproduction and focuses attention on understanding the problem and ensuring that it never recurs. Please share this on facebook. if you […]

What is Andon

Andon – Definition A device that calls attention to defects, equipment abnormalities, other problems, or reports the status and needs of a system typically by means of lights – red light for failure mode, amber light to show marginal performance, and a green light for normal operation mode. Please share this on facebook. if you […]