The Lean Toolbox

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Lean Production Toolbox
The toolbox for all lean activities

Elimination of all Waste

Cost and Market Leadership

Level 1 Enabler Level 2 Basics Level 3 Experts Level 4 Pro-Tools

Total
Obeyaka / Inbound Mizusumashi / Safety / Heijunka /
Standardization Lean Training Productive
Lean Layout Milkrun Tow Train Ergonomics Leveling
Maintenance

Operator-
The 24 Lean Production One Piece Yamazumi / Mixed Model
5S Takt Time Zero Buffer Process Supermarket
Methods and Tools Flow Line Balancing Line
Flexibility

3P /
Small-sized SMED 2-Box Jidoka /
Visualization Andon Pull / Kanban Design for
Packaging Changeover Principle Hanedashi
Manufacturing

Create a Vision
Lean Self-Assessment / Value-Stream-Design (VSD) *derived from the Toyota
Production House

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Implement straight assembly
Obeyaka /
line layouts for tremendous
Lean Layout
cost reductions.
Implement visual
management and
5S
transparency to reduce
costs and quality risks.
Decrease lot-sizes to
Small-sized
increase shop floor
Packaging
dynamics.
Link supplier deliveries to
Inbound
reduce operational costs
Milkrun
significantly.
Be clear about your takt
Takt Time time calculation and
customer demand.
Reduce changeover time to
SMED reduce machine and
Changeover operational costs
significantly.
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Lean Production Toolbox
Reduce safety risks and
Total
Mizusumashi / In-house material supply to Safety / failures by implementing the Implement the idea of
Productive
Tow Train the assembly line. Ergonomics right lean tools at the shop preventive maintenance.
Maintenance
floor.
Eliminate high rack shelves,
Elimination of waste and implement supermarkets to Mixed Model The highest level of a lean
Zero Buffer Supermarket
inventory. supply your assembly Line production.
efficiently.
Eliminate push production,
Set clear rules,
implement a consumption- Jidoka / Implement autonomation
Visualization responsibilities and Pull / Kanban
based pull process based on Hanedashi and simple solutions.
structures.
Kanban.
Level your production and
Visualize deviations by Train your staff, coach your Heijunka /
Standardization Lean Training produce day by day with an
standardizing processes. management. Leveling
equal output.
The killer tool for any lean
Eliminate shop production
Operator- Increase flexibility to react to specialist: Reduce
One Piece and implement a one piece Yamazumi /
Process customer demand operational costs
Flow flow to reduce costs and Line Balancing
Flexibility immediately. tremendously with the
space significantly.
Yamazumi chart.
Design your products in a
Implement failure signals to 3P /
2-Box Build a foundation for the way in which assembly time
Andon decrease your response- Design for
Principle pull and Kanban process. can be reduced to a
time to machine downtimes. Manufacturing minimum.
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Including deep insights into the 24 Tools of Lean Production

http://www.lean-toolbox.org/book

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