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## The Secret Weapon of Lean Manufacturing You Might Be Overlooking \(and It Boosts Your Bottom Line\) In the fast-paced world of manufacturing, every second and resource counts. But there's an often-underrated hero hiding in plain sight: Standardized Work. **#leanmanufacturing** **#manufacturing** This isn't just about writing down procedures. It's about streamlining processes for maximum efficiency, reduced waste, and consistent quality. **#efficiency** **#qualitycontrol** **Here's how standardized work can transform your operation:** * **Reduced waste & errors** \(think: less rework, more output!\) * **Enhanced quality control** \(say goodbye to inconsistencies!\) * **Faster onboarding & training** \(new hires get up to speed quicker\) * **Continuous improvement** \(always striving to be better\) * **Empowered & engaged workforce** \(clear expectations = happy employees!\) **Ready to unlock these benefits?** My latest blog post dives deep into standardized work and how to implement it for a leaner, more profitable operation! **#manufacturingtips #leanmanufacturingtips #productivity** https://lnkd.in/gAb9MiaG
Standardized Work: The Unsung Hero of Lean Manufacturing
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As an industrial engineer and operations consultant who has been in manufacturing operations for 22 years, I know for fact that lean systems would work if implemented correctly and if you get the people involved in it the right way. We believe in people. We have learned everyone wants to do a good job; however, in many cases, the definition of a good job is not known or people have not been trained to that standard, specially in manufacturing. That’s why we built Routine. We can put you in front of our happy clients with 4,000+ users to share their success story with you.... some feature that your team can benefit from: 💎 Track documents from inception to publication to revision and beyond. 💎 Tie Operation to safety, quality, people and assets such as machineries and tools 💎 Training management module tied to operations to keep work instruction and organizational knowledge current 💎 Real Time Translation to 18 different Languages 💎 Ability to connect to ERPs using API connections 💎 Create and maintain Standard Work and critical process documents that can include images, videos, diagrams, etc. 💎 Build a real time training matrix with no additional administration work. https://lnkd.in/gH738FMs
Optegrity Routine- Shopfloor Operations Management- Better than ever
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The Role of Routine in Lean Manufacturing https://lnkd.in/gV-EzjBy #LeanManufacturing #Routine #Efficiency #ContinuousImprovement #ManufacturingExcellence #Productivity #Standardization #LeanPrinciples #Kaizen #OperationsManagement
The Role of Routine in Lean Manufacturing
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A result-driven Executive with 20+ year of experience in productivity enhancement, material flow optimization and cost reduction. Engaging Leader able to communicate effectively and promote cultural transformation.
Lean & Quality
Kaizen approach: How lean manufacturing elevates quality standards in manufacturing? - ET Government
government.economictimes.indiatimes.com
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Knowledgeable articles in Manufacturing excellence. What are the 16 Major Losses in TPM? All Losses are divided into three groups: Availability Losses, Performance Losses, and Resource Consumption Losses. Availability Losses 1. Breakdown loss-Breakdown or failure loss occurs when a machine fails and is unable to be operated, runs at a lower-than-normal rate, runs with occasional stoppages, needs a part replacement to function properly, needs repairs. 2. Planned maintenance loss - When equipment is shut down for a planned inspection or maintenance. 3. Setup & adjustment loss-This loss relates to changeovers, either between tools or the production of different articles. 4. Cutting blade change loss-The time it takes to replace a worn-out, broken, or ineffective cutting tool. 5. Startup loss -Similar to adjustment loss, startup loss occurs when bringing a piece of equipment into an optimal operating state after a shutdown. 6. Minor stoppage loss - Minor stoppages can last from only a few seconds to several minutes. This loss is persistent and regular, and oftentimes difficult to detect. 7. Speed loss- Speed loss expresses the lost time that’s incurred due to a machine running slower than its standard speed. 8. Defect and rework - When a machine is producing articles of sub-optimal quality that require time to be fixed, defect and rework loss occurs. Performance Losses This group of losses is expressed in both time and money, and primarily relates to losses that are related to the human workforce. 9. Management loss - production stop due to insufficient spare parts, operators, or tools. 10. Operating motion loss - due to pointless or superfluous operator movement, often caused by a sub-optimal layout of the shop floor. 11. Line organization loss -when the speed of the different steps on a line is unbalanced, causing certain operators to be idle. 12. Distribution / Logistics loss -This loss applies to everything related to the delivery of products to a factory (e.g. raw materials). 13. Measurement & Adjustment loss - If the quality of products is consistently sub-optimal and the root cause can’t be found, the consequence is often an excessive number of adjustments to machine settings (so as to keep product quality consistent). This constant inspecting and adjusting can lead to a significant waste of time. Resource Consumption Losses Resource consumption losses—expressed in money—occur when energy, materials, or parts are used in an ineffective manner. 14. Yield loss- Yield loss expresses the loss that occurs when a part of the total production output has to be discarded because of defects. 15. Energy loss- Energy loss encompasses waste due to the direct material loss of energy and its inefficient use. 16. Die & tool loss - The last of the 16 Major Losses in TPM applies to the cost of the items needed for jig and die repairs, tool replacements, machine restorations
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📚 What Went Wrong? A Deep Dive into Manufacturing Management 📚 1️⃣ **Scientific management** evolved into **mathematical management**, reducing the manufacturing management problem to analytically tractable subproblems. But we need a better framework for applying these in the context of an overall business strategy. 2️⃣ **Information technology** without a suitable model of the flow process is fundamentally flawed. For instance, MRP uses an infinite-capacity, fixed-lead-time approach to control work releases, a fundamental flaw carried over into ERP and SCM. 3️⃣ Other “scientific” approaches, such as **business process re-engineering**, have typically exhorted managers to rethink their processes without providing a framework for doing so, often becoming too closely identified with exclusively radical solutions and downsizing. 4️⃣ **Lean manufacturing** provides many useful tools for improving operations but does not offer a general approach for improving any operation, nor does it offer a comprehensive systems analysis paradigm. Value stream mapping provides a good start but does not go far enough to provide solutions to many real problems. 5️⃣ **Six Sigma** is based on the scientific method, particularly the experimentation step. However, Six Sigma does not provide a paradigm for organizing and retaining the knowledge obtained from experiments. Moreover, while the DMAIC procedure is useful in determining causes and implementing variability controls, it does not offer a comprehensive tool set. In practice, the morphing of JIT and TQM into lean and Six Sigma has resulted in more robust methods. However, we are left with sets of techniques rather than comprehensive systems. The many creative insights of the JIT and TQM founders need a subtler, more complex framework to be fully understood and applied correctly. They need a science of manufacturing. Manufacturing is complex, large scale, multi objective, rapidly changing, and highly competitive. There cannot be a simple, uniform solution that will work well across a spectrum of manufacturing environments. Moreover, even if a firm can come up with a system that performs extremely well today, failure to continue improving is an invitation to be overtaken by the competition. Ultimately, each firm must depend on its own resources to develop an effective manufacturing strategy, support it with appropriate policies and procedures, and continue to improve this over time. As global competition intensifies, the extent to which a firm does this will become not just a matter of profitability, but one of survival. Will we learn from history, or will we continue to be diverted by the allure of a quick fix? Will we bring ideas together within a rational scientific framework or will we simply continue to play the game making up new buzzwords. Or, worse, will we grow tired and begin to simply concatenate existing buzzwords, as in the case of the “lean sigma”?
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Life and business strategist, philanthropist, entrepreneur, brand developer, marketing mastermind, published writer and author.
Leveraging Lean Manufacturing for Enhanced Profitability: Lean Manufacturing has emerged as a pivotal strategy for driving profitability in the current dynamic economic landscape. By embracing Lean principles, businesses can streamline operations, enhance product quality, and ensure customer satisfaction, ultimately leading to increased profitability. At the core of Lean Manufacturing is reducing waste across the value chain. By implementing strategies like Just-in-Time (JIT) production and Kanban systems, organizations can minimize excess inventory, overproduction, and defects, leading to significant cost savings and improved resource allocation. Lean Manufacturing emphasizes process streamlining and workflow optimization, enabling companies to identify and eliminate bottlenecks. Techniques such as Value Stream Mapping (VSM) and Kaizen events facilitate identifying and eliminating non-value-adding activities, resulting in heightened productivity, reduced lead times, and improved operational efficiency. Lean Manufacturing prioritizes quality at every stage of production. Through methodologies like Total Productive Maintenance (TPM) and Six Sigma, organizations can detect and address production issues, leading to decreased defects and improved product quality. Enhanced quality not only reduces rework costs but also contributes to increased customer satisfaction and loyalty, bolstering long-term profitability. Efficient resource utilization is a crucial focus of Lean Manufacturing. By implementing standardized work procedures and cross-training initiatives, companies can ensure their workforce is versatile and adaptable, leading to optimized production capabilities. Tools like Overall Equipment Effectiveness (OEE) and Single-Minute Exchange of Die (SMED) also help minimize equipment downtime, resulting in improved resource allocation and reduced overhead expenses. Lean Manufacturing underscores the importance of flexibility in meeting changing market demands. Practices such as Just-in-Time production enable companies to adjust output levels in response to real-time customer orders, reducing the risk of overproduction and excess inventory. This flexibility allows businesses to align production with market fluctuations, seize new opportunities, and maintain a competitive edge, ultimately enhancing profitability. Lean Manufacturing extends its benefits to the optimization of the entire supply chain. Companies can minimize lead times, reduce inventory costs, and improve supply chain visibility by fostering collaborative relationships with suppliers and implementing techniques such as Vendor-Managed Inventory (VMI) and collaborative planning, forecasting, and replenishment (CPFR). This optimized supply chain facilitates prompt response to customer demands while lowering overall supply chain expenses, contributing to increased profitability.
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Gain insights from the success stories of industry giants in applying lean manufacturing principles for operational excellence. Learn from the best! https://hubs.la/Q02CtK5G0
Worximity | Lean Manufacturing Examples & Insights from Top Industry Leaders
worximity.com
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Lean Six Sigma combines Lean's focus on waste reduction with Six Sigma's emphasis on minimizing defects. This scientifically curated method empowers front-line operations to achieve excellence. Standard work instructions play a pivotal role in this synergy, providing clear, standardized guidance to frontline workers, ensuring optimal performance and reduced errors. Benefits of Lean Six Sigma Integration: 🔹 Enhanced Customer Satisfaction 🔹 Reduced Costs and Waste 🔹 Strengthened Quality and Consistency 🔹 Streamlined Processes and Standardized Procedures Read our full blog to dive deeper into its principles and how to implement them for operational success! #LeanSixSigma #workinstructions #OperationalExcellence #principles #connectedworker #IndustrialAR
Lean Six Sigma Principles: Work Instructions Excellence Guide
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Back to defining operations. Check it out! https://lnkd.in/g9HwC8NC #OperationalExcellence #LeanManufacturing #ContinuousImprovement #Lean #OptegritySolutions #HelpingExcellenceFlow
Optimal Modularity in Manufacturing Operations: Lessons from the Bill of Operations
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