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Lean Manufacturing Topics

Overview

Our goal is to make it much easier for you to understand the core concepts of lean manufacturing. We also cover related topics that are critical to improving manufacturing productivity, such as The Theory of Constraints. For many topics, we present both the theory behind the concepts along with a very practical implementation roadmap.

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Introduction to Lean

Top 25 LEAN manufacturing tools. Get started with LEAN manufacturing concepts

Top 25 Lean Tools

Top 25 most important lean tools.

Lean has a very extensive collection of tools and concepts. Surveying the most important of these, understanding both what they are and how they can help, is an excellent way to get started.

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Essence of LEAN manufacturing – Eliminate manufacturing waste and improve manufacturing productivity

The Essence of Lean

Eliminate Waste. Improve Productivity.

In order to improve efficiency, effectiveness, and profitability, focus relentlessly on eliminating all aspects of the manufacturing process that add no value from your customer’s perspective.

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Increase factory production with these three steps to improve manufacturing productivity

Improve Production Today

Three steps to improve productivity today.

Amazing improvements in productivity can be achieved through small daily increments. Each day, ask three simple questions (one each for Information, Decision, and Action) that lead to one specific action.

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Lean Topics

Steps of the 5S Process: Sort, Straighten, Shine, Standardize, and Sustain

5S

A neat workspace means less wasted time.

5S is a five step methodology for creating a more organized and productive workspace: Sort, Straighten, Shine, Standardize, and Sustain. 5S serves as a foundation for deploying more advanced lean production tools and processes.

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Agile Manufacturing: 4 components of Agile that reduce lead time

Agile Manufacturing

Reduce lead time. Be more competitive.

Manufacturers can achieve a significant structural advantage over offshore competitors by leveraging proximity to local markets to deliver new and highly personalized products with unprecedented speed.

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Hoshin Kanri aligns corporate strategy with plant floor actions to increase productivity and decrease waste

Hoshin Kanri

Align strategy to manager and operator actions.

Align company goals (Strategy) with the plans of middle management (Tactics) and work performed by employees (Operations) to ensure that everyone is pulling in the same direction at the same time.

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Kaizen is manufacturing philosophy that creates a continuous improvement action plan to reduce manufacturing waste

Kaizen

Deliver regular, incremental improvements.

Create a culture of continuous improvement where all employees are actively engaged in improving the company. Nurture this culture by organizing events focused on improving specific areas of the company.

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OEE waterfall chart with the OEE Loss factors

OEE (Overall Equipment Effectiveness)

A yardstick for measuring manufacturing productivity.

OEE measures the percentage of planned production time that is truly productive. Many manufacturing lines are only 60% productive, meaning there are tremendous opportunities for improvement.

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Short Interval Control uses historical analysis and identifies future production risks to plan the shift

Short Interval Control (SIC)

Small actions add up to large improvements.

Quick and focused reviews of performance data during the shift enable mid-course corrections and immediate small-scale fixes that collectively result in significant improvements in performance.

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Streamline changeover processes with the three major phases of SMED (Single-Minute Exchange of Die)

SMED (Single-Minute Exchange of Die)

Reduce changeovers to under 10 minutes.

Changeover times can be dramatically reduced – in many cases to less than 10 minutes. Each element of the changeover is analyzed to see if it can be eliminated, moved, simplified, or streamlined.

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The five focusing steps of the Theory of Constraints are used to identify and decrease manufacturing bottlenecks

Theory of Constraints

Focus on the bottleneck to improve throughput.

Every process has a constraint (bottleneck) and focusing improvement efforts on that constraint is the fastest and most effective path to improved profitability.

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Total Productive Maintenance (TPM) consists of 5S and eight supporting activities

TPM (Total Productive Maintenance)

Engage operators to maximize equipment effectiveness.

Getting operators involved in maintaining their own equipment, and emphasizing proactive and preventive maintenance will lay a foundation for improved production (fewer breakdowns, stops, and defects).

> Explore TPM (Total Productive Maintenance)