Lean Tools

 What are the various Lean Tools?

Lean can be defined as a set of management practices or techniques that can improve efficiency and effectiveness by removing waste. Lean works on the core principle of minimizing and eliminating non-value-added activities to cut down waste.

There are various lean tools and concepts and each one is unique and contributes extensively to the reduction and removal of waste. Lean Tools Online Training is available to learn the various lean tools and how to apply the respective tool suitable for your organization.


In this article, we will discuss the various lean tools and a short description of the most widely used lean tools and how each lean tool can improve waste in the manufacturing process.


Various Lean Tools

  1. 5S

  2. Andon

  3. Bottleneck Analysis

  4. Continuous Flow

  5. Gemba (The Real Place)

  6. Heijunka (Level Scheduling)

  7. Hoshin Kanri (Policy Deployment)

  8. Jidoka (Autonomation)

  9. Just-In-Time (JIT)

  10. Kaizen (Continuous Improvement)

  11. Kanban (Pull System)

  12. KPIs (Key Performance Indicators)

  13. Muda (Waste)

  14. Overall Equipment Effectiveness (OEE)

  15. PDCA (Plan, Do Check, Act)

  16. Poka-Yoke (Error Proofing)

  17. Root Cause Analysis

  18. Single-Minute Exchange of Dies (SMED)

  19. Six Big Losses

  20. SMART Goals

  21. Standardized Work

  22. Takt Time

  23. Total Productive Maintenance (TPM)

  24. Value Stream Mapping

  25. Visual Factory


5S

5S is the most commonly used lean tool across various manufacturing sectors and industries. Attend 5S Virtual Training to understand to develop your ability to lead 5S in your workplace.

5S works in the order of:

  1. Sort (Seiri in Japanese)

  2. Set in Order (Seiton in Japanese)

  3. Shine (Seiso in Japanese)

  4. Standardize (Seiketsu in Japanese)

  5. Sustain (Shitsuke in Japanese)


Gemba

The literal translation of Gemba means the real place. Gemba works on the principle of moving out of our desk area and visiting the shop floor or plant floor - the place where the real action is taking place.


Kaizen

Also known as Continuous Improvement, Kaizen is a strategy wherein all the employees work in tandem to bring incremental improvement.


Kanban

Also known as Pull System, Kanban works as a method to regulate goods inside the factory as well as with the suppliers and customers.


KPI

Kep Performance Indicators (KPIs) are metrics that are designed to keep track of the progress towards critical goods. Extremely powerful KPIs drive desired behaviors.


Muda

Also known as Waste, Muda means anything in the manufacturing process that does not add any value as per the customer’s perspective. Eliminating Muda or waste is the primary goal of the lean manufacturing process.


PDCA

Referred to as Plan, Do Check, Act is an interactive methodology for implementing improvements in the workplace. 

  • PLAN - Establish a Plan

  • DO - Implement the Plan

  • CHECK - Verify the results

  • ACT - Evaluate and Assess and repeat the process

Poka-Yoke

Also known as Error Proofing, this lean tool helps to detect and prevent errors in the design and production process. This works with the goal of achieving zero defects.


Root Cause Analysis

A problem-solving methodology, this tool focuses to resolve any underlying problem instead of doing a quick fix. Asking at least five times is a common approach of this tool to move a step closer to discover the underlying problem.


Value Stream Mapping (VSM)

This is a tool that visually maps the flow of production and highlights improvement opportunities. VSM exposes waste in the existing process and provides an improvement roadmap.

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