Lean manufacturing free software

Lean is centered on reducing anything that does not add value. They are therefore waste. Muda means waste, uselessness or idleness.

Muda Type -II : Unnecessary non value-added activity e. TPS lists 7 types of Muda: 1. Transport — moving products that are not actually required for a process 2. Inventory — all parts, work in process and finished parts not being processed 3. Motion — people or equipment moving or walking more than required for the process 4. Waiting — waiting for the next step in production 5.

Overproduction — producing more than demand 6. Continuous flow is a Lean manufacturing tool that involves using smaller batch sizes to increase the speed and efficiency of production. Continuous flow refers to the state of continuously, consistently delivering outputs by moving each item through each step of the process, instead of processing items in batches. Producing in smaller batches also allows teams to regularly examine the output to make any necessary improvements for the next batch, thereby eliminating waste.

Cellular manufacturing supports continuous flow by calling on teams to arrange workstations based on the parts they produce in order to minimize travel time for those parts and allow for rapid feedback across stations about any issues. Together, these two Lean manufacturing tools also enable teams to produce smaller, more efficient batches.

In their original Japanese, the five steps of the 5S system each begin with the letter S, which is where the system gets its name: Seiri, Seiton, Seiso, Seiketsu, Shitsuke. These terms have been translated into English, conveniently also all beginning with the letter S:. For a more in-depth explanation of the 5S Lean system and how to implement it, we recommend this article.

This Lean tool, and the following one, work together as the key operational activities of a quality management system. Total Quality Management refers to organization-wide efforts to install and maintain an environment where employees continuously improve their ability to produce high-quality products on demand.

Total Productive Maintenance TPM is a Lean manufacturing tool that aims to increase operational efficiency of equipment and safety for workers. While TQM focuses on continuously improving the quality of products being produced, TPM focuses on increasing the volume of production by maintaining the reliability of equipment.

TPM blurs the roles of production and maintenance by empowering operators to help maintain their equipment. The goals of TPM are to achieve a state of perfect production, which means:.

The 5S system is the foundation of TPM. The 5S system is a useful Lean manufacturing tool that creates a work environment that is clean and well-maintained. There are eight supporting activities of TPM that build upon this foundation:. OEE is based on scores for availability, performance speed and output quality. Takt time is one of the Lean manufacturing tools focused on measuring customer value. It measures the average rate at which teams must manufacture products to meet demand.

To calculate takt time, divide the working time available for production in hours, days, weeks by the units required to meet customer demand. Using this Lean manufacturing tool, if a team works 40 hours a week and the company expects customers to buy 80 units a week, the takt time is 0.

MfgTracker - Manufacturing Data Tracker v. So many companies waste time replicating this effort. Help stop the madness. Open Source Aided Manufacturing v. Holonic Manufacturing Systems v.

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