Question

A key Lean Principle is Create Flow. Identify three tools that support or promote flow in a manufacturing company. Describe how they help the flow of production.

Answer 1

1. Kaizen

Kaizen is a Japanese word that translates to ‘continuous improvement’. It refers to the processes that can improve the efficiency of the manufacturing process. In Kaizen, the employees work proactively as one cohesive unit to make incremental progress in the manufacturing department. In simple words, it unites the collective talents in a company to enhance the efficiency of the organizational activities.

1. The pain point is identified and focused on
2. The current method to tackle the problem is carefully analyzed.
3. Improved methods and tactics are tried, tested, and reviewed.
4. The newly found method is implemented
5. The results and benefits are analysed and put in front of the upper management.

As an application, when implemented successfully, it promotes innovative thinking among employees and develops an efficient and effective culture. Employees are constantly looking for small ways to improve the process and these incremental changes lead to major benefits for the organization.

2. One-Piece Flow

One-piece flow, which works on the same principles as Just in Time, is a production method that is used in place of the traditional method of production. When production is in bulk, the materials proceed through the manufacturing process in batches which is not an efficient method. In one-piece flow, one product is completed before the next product is started. By adopting this method, the waiting time is negligible and the manufacturing process moves smoothly. Moving products in bulk consume a lot of time, but one-piece flow only processes and produces what is required at the moment, thus reducing wastage.

3. Jidoka

Jidoka is one of the most effective methods to enhance the supply chain of an organization. It prevents the delivery of low quality nd defective products to the consumers. Jidoka relies on four basic principles:

1. Identify a defect.
2. Put a halt to the manufacturing process.
3. Rectify the immediate problem.
4. Scrutinize and solve the root cause.

Implementation of Jidoka enables anyone in the company to pause the workflow as soon as they observe any defect that might compromise the quality of the product. It enables an organization to inspect the issue in the middle of the process rather than the end thereby adding an extra dimension of human judgement to an automated process.