Just in Time by Toyota: The Smartest Production System in The World

Lean manufacturing and just-in-time production both have their roots in the revolutionary Toyota Production System. The Toyota Production was developed between 1948 and 1975 and is now a common management philosophy that is practiced in some of the biggest companies in the world. TPS aims to have a facility that is operating efficiently, is not overburdened or wasteful, and that production is level. Having a flexible manufacturing process that runs smoothly is what TPS is …

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Introduction to the 8 Wastes of Lean Manufacturing

Do you know the wastes of Lean? The original 7 Wastes of Lean are recognized by the Toyota Production System as the most common wastes manufacturers face. An eighth waste has been added however, and the philosophy is now referred to as the 8 Wastes of Lean. The different tools and strategies that Lean encompasses all work to address these wastes, which makes being able to spot them in your workplace that much more important. …

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5S Revealed – 5S and the Visual Workplace

5S is a popular strategy used in Lean workplaces as a means to make the facility easier to navigate, find what they need, and keep things organized. Both 5s and Lean rely on the use of visual cues for success. Using floor markings, signs, labels, and a color coding system will help to quickly communicate important information to employees. This DVD was released by Creative Safety Supply and shows you a preview of the DVD, …

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Lean Manufacturing – Lean Factory Tour – FastCap

Having a Lean facility means to have a facility promoting efficiency and the reduction of waste. Work cells are organized in a logical manner and easy to navigate while equipment and tools have their own spaces that are out of the way. A Lean facility will often use visual communication, and you can tell workers are able to work quickly and efficiently. FastCap gives an excellent tour of their Lean facility in this video. A …

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How to do Value Stream Mapping

Value stream mapping is a Lean activity focused on identifying areas of improvement in processes. A value stream map is a hand-drawn diagram of a workplace that shows the flow of materials moving through different areas. The map should have more information on it including how long tasks take and how often orders for materials are placed. There are many benefits of creating a holistic view of the entire current system including the ability to …

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Learn How Kanban Systems are Used in a Lean Manufacturing Environment

  A popular tool used in Lean businesses is a tool called Kanban, a Japanese word meaning sign. It is used in the just-in-time system of production as a means of regulation. In terms of manufacturing, a Kanban system usually uses a bin and card system that triggers a certain action. For instance, the production line may not start production on a new product until the visual cue is sent from the sales department. This …

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What is Six Sigma?

 Six Sigma is quality-management strategy often used in Lean manufacturing. It focuses on quality control and its principles have been established from several Lean methods. The main waste Six Sigma works to eliminate are defects. Defects in processes or the product will ultimately cost the business time and resources. A prime example of Lean’s influence on Six Sigma is the DMAIC model, which was influenced by Deming’s (a Lean pioneer) Plan-Do-Check-Act cycle. The Six …

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Gemba is a Powerful Piece of a Lean Toolbox

Have you taken a Gemba walk around your facility before? Gemba is a Japanese term meaning “the real place” and is an important tool for any Lean workplace. A Gemba walk is a scheduled walk that company leaders take around the facility to see processes up close and talk with frontline workers. Managers and supervisors can learn a ton from a Gemba walk by personally connecting with the work up close. It fosters communication and …

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Learn What 5S is & How it Applies to Any Industry

A strategy often used in Lean is 5S. 5S is an organizational framework that relies on visual management and offers steps to organize spaces, eliminate wastes, and increase efficiency. The methodology of 5S is comprised of the following five steps: Sort, Set in Order, Shine, Standardize, and Sustain. Putting time and effort to each step will make the facility an easier place to work, an ultimately make the workplace function better. This video comes the …

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The Toyota Production System

The tools, strategies, and philosophy of Lean manufacturing are derived almost entirely from the Toyota Production System. To understand Lean, one must understand the Toyota Production System. TPS is focused on seven (or eight) different wastes commonly found in a manufacturing facility. By reducing or eliminating these wastes, the overall customer value improves. The Toyota Production System uses a number of tools to meet that goal like Kaizen, Heijunka, and Jidoka. This video comes from …

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