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waste
from the manufacturing
process.
So, what is waste? It can take many forms, but the basic idea is to eliminate anything and everything that
does not add value from the perspective of your customer.
Another way to look at lean manufacturing is as a collection of tips, tools, and techniques (i.e. best
practices) that have been proven effective for driving waste out of the manufacturing process.
Lets talk a bit more about waste. Traditional lean identifies seven key areas of waste typically referred to
as the Seven Deadly Wastes. These are described below along with suggested countermeasures. Dont worry
if the countermeasures are not immediately actionable for you right now they can be considered simply
as a roadmap for the future.
Seven Deadly
Wastes
Description
Waiting
Transport
Motion
Unnecessary movement of
Mapping).
Overprocessing More processing than is needed
to produce what the customer
requires. This is often one of the
more difficult wastes to detect
and eliminate.
Inventory
Defects
Lean concepts become a lot more intuitive and easy-to-understand when they are traced to the ultimate
goal eliminating waste.
much easier to get started. On the other hand, the benefits will compound as more tools are used, as they
do support and reinforce each other.
The following is a collection of 25 essential lean tools. Each tool is distilled into a simple description of what
it is and how it helps.
Lean Tool
What Is It?
Andon
Bottleneck
Analysis
Continuous Flow
Heijunka (Level
Scheduling)
Hoshin Kanri
(Policy
Deployment)
Jidoka
(Autonomation)
Just-In-Time
(JIT)
5S
space requirements.
Kaizen
(Continuous
Improvement)
Kanban (Pull
System)
KPI (Key
Performance
Indicator)
Muda (Waste)
Overall
Equipment
Effectiveness
(OEE)
Do (run experiment)
Do (implement plan)
Poka-Yoke (Error
Proofing)
Root Cause
Analysis
underlying problem.
Single Minute
Reduce setup (changeover) time to less
Exchange of Die
than 10 minutes. Techniques include:
(SMED)
Eliminate non-essential
operations
Six categories of productivity loss that are Provides a framework for attacking the
almost universally experienced in
most common causes of waste in
manufacturing:
manufacturing.
Breakdowns
Setup/Adjustments
Small Stops
Reduced Speed
Startup Rejects
Production Rejects
SMART Goals
Standardized
Work
Takt Time
Total Productive
Maintenance
(TPM)
Value Stream
Mapping
Visual Factory