DIAGNOSTICS LEAN.
Addressing an improvement project or transformation of a factory or section requires an initial analysis or diagóstico, about the philosophy of Lean Manufacturing.
Lean Diagnosis allows to know the level of excellence of the company, evaluating aspects such as:
Organization, order and cleanliness: 5S When jobs are organized, neat and clean, people who occupy them are proud of it and improves its involvement with the company. The level of organization, order and cleanliness of a company can predict the level of excellence. Therefore, companies that implement Lean Manufacturing are the most organized and clean. The tool to achieve this effect are 5S.
People. People are the most important resource in the company. The degree of motivation and involvement having revert directly to the competitiveness of the company. The shift towards a Lean company will necessarily teamwork, continuous improvement and elimination of waste by all staff.
Standardized work. The way companies guarantee the continuity of knowledge of its employees, even when they are gone, it is through standardization. Working with standards can enhance the process of continuous improvement.
Just in time. Production processes to work well requires that the internal logistics that interrelates will too. When certain level of stability has been achieved on the ground, the company can begin to reduce the inventory of material in process and raw materials. By JIT it will be possible to get the “right amount” of the “necessary part” in the “right place” and the “right time.”
Jidoka (manufacturing quality). Any defective product passing to the next process is a waste that comes at a cost. Jidoka means manufacturing quality. According to this premise they create a series of procedures and mechanisms to stop production at the moment any quality problem is detected. The aim of companies implementing Lean Manufacturing is to achieve “zero defects”.
Total Productive Maintenance. The TPM is the tool that will allow machines are available at the right time. Traditional, corrective and preventive maintenance is no longer sufficient. The production staff participation through the Autonomous Maintenance and management of continuous improvement, through Focused Improvement Groups, achieved remarkable advances in productivity and costs.
Quick change tools and formats. Companies have increased their number of references and, increasingly, orders are fewer units. It should reduce change times in order to not descend productivity values. The SMED (Single Minute Exchange Die) is the tool that allows this.
The most common diagnostic tools are:
- Map value chain VSM (Value Stream Map)
- Calculation of OEE (overall efficiency of equipment and processes)
- Lean assessment Listings
