Top 32 technologies
- 1. TOP 32 TECHNOLOGIES 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 5S ABC Inventory Andon Bottleneck Analysis Cellular Manufacturing Continuos Flow The A items are extremely important, and typically high volume or high value item. B items are moderately important. C items are a low priority and typically low volume items. The system is used to define inventory stock levels, reorder points and cycle counting frequencies for items. Andon acts as a real-time communication tool for the plant floor that brings immediate attention to problems as they occur - so they can be instantly addressed. Bottleneck Analysis studies a process to identify the step in the process where the capacity available is less than the capacity required. The process is known as the constraint. The next step is to identify ways of removing the constraint. Improves throughout by strengthening the weakest link in the manufacturing process. Cellular Manufacturing is an approach in which all equipment and workstations are arranged based on a group of different processes located in close proximity to manufacture a group of similar products. The primary purpose of cellular manufacturing is to reduce cycle time and inventories to meet market response items. ERP systems are Enterprise resource Planning systems, These large scale computer systems enable information flow throughout an organization, and with other organizations. An ERP system provides the processes for planning. monitoring and reporting on all supply chain, manufacturing and sales activities. ERP In the Analyze phase, the absence of concrete statistical data sometimes can make the identification of a root cause difficult. In those scenarios, the 5 Whys asking "Why?" five times along with a cause and effect diagram, can make the task more manageable. The 5 Why's tool also can help uncover the process dyna,ics and the areas that can be addressed easily. The vest manufacturing KPIs : * Are aligned with top - level strategic goals / thus helping to achieve those goals) * Are effective at exposing and quantifying waste (OEE is a goof example) * Are readily influenced by plant floor employees (so they can drive results) Provides a benchmark / baseline and a means to track progress in eliminating waste from a manufacturing process. 100% OEE means perfect production (manufacturing only good parts, as fast as possible, with no down time). Applies a scientific approach to making improvements: PLAN - Develop a hypothesis DO - Run experiment CHECK - Evaluate Results ACT - Refine your experiment; Try Again Creates a shared responsibility for equipment that encourages greater involvement by plant floor workers. In the right environment this can be very effective in improving productivity (increasing up time, reducing cycle times, and eliminating defects). Zero Quality Control is a methodology designed to shift quality to the process and eliminate the need for external quality inspections. A zero quality control system typically includes error - proofing, "Source inspection" and employee empowerment as well as other quality initiatives. Eliminate waste that results from a poorly organized work area (Eg. Wasting time looking for a Tool) Eliminate many forms of waste (Eg. Inventory, Waiting Time, Transport) Reduces lead times (since each product or variant is manufactured more frequently) and inventory (since batches are smaller). Gemba (The Real Place) Heijunka (Level Scheduling) Promotes a deep and thorough understanding of real - world manufacturing issues - by first hand observation and by talking with plant floor employees. Hoshin Kanri (Policy Deployment) Ensures that progress towards strategic goals is consistent and thorough - eliminating the waste that comes from poor communication and inconsistent direction. IIshikawa (Cause and Effect) Diagram and 5 Whys Jidoka (Autonomation) After Jidoka, workers can frequently monitor multiple stations (reducing labor costs) and many quality issues can be detected immediately (improving quality) Just - In - Time (JIT) Highly effective in reducing inventory levels. Improves cash flow and reduces space requirements. Kaizen (Continuous Improvement) Combines the collective talents of a company to create an engine for continually eliminating waste from manufacturing processes. Kanban (Pull System) Eliminates waste from inventory and overproduction. Can eliminate the need for physical inventories (instead relying on signal cards to indicate when more goods need to be ordered). KPI (Key Performance Indicator) Level Loading Level loading is a production scheduling technique where production is smoothed out over short time horizons to distribute work evenly, thereby creating a consistent and achieveable production plan. Mind Maps Mind maps are a visual tool used to organize and present interrelated ideas. This tool is similar to cause and effect diagrams and other mapping tools. Mind maps offer great flexibility and can present complex systems in a very easy to understand format. Muda (Waste) Eliminating muda (waste) is the primary focus of lean manufacturing. Overall Equipment Effectiveness (OEE) PDCA (Plan, Do, Check, Act) Poka - Yoke (Error Proofing) It is difficult (and expensive) to find all defects through inspection, and correcting defects typically gets significantly more expensive at each stage of production. Root Cause Analysis Helps to ensure that a problem is truly eliminated by applying corrective action to the "root cause" of the problem. Single Minute Exchange of Die (SMED) Enables manufacturing in smaller lots, reduces inventory, and improves customer responsiveness. Six Big Losses Provides a framework for attacking the most common causes of waste in manufacturing. SMART Goals Goals that are: Specific, Measurable, Attainable, Relevant, and Time - Specific. Helps to ensure that goals are effective. Standardized Work Eliminates waste by consistently applying best practices. Forms a baseline for future improvement activities. Takt Time Provides a simple, consistent and intuitive method of pacing production. It is easily extended to provide an efficiency goal for the plant floor (Actual Pieces / Target Pieces). Total Productive Maintenance (TPM) Value Stream Mapping Exposes waste in the current processes and provides a roadmap for improvement through the future state. Visual Factory Makes the state and condition of manufacturing processes easily accessible and very clear to everyone. Zero Quality Control Infographic by, D. B. Naga Muruga Dept of Mech Engg, Sriram Engineering College Credits ; nagamuruga403@gmail.com