Featured Stories

Categories

5 lean techniques that will improve your manufacturing processes

Eric Fogg
September 02, 2016

 

 

lean_manufacturing.jpg

 

Interested in lean techniques that can have a beneficial impact on your manufacturing processes?

With a number of great lean strategies out there, how do you find the one that will have the most impact in your business?

A good approach is to review the lean techniques that are currently proving themselves where it matters most - on the shop room floor.

Here is a brief description of 5 effective lean strategies along with an explanation of how each tool can improve your manufacturing processes.

Keep in mind, although each of these lean techniques can have a dramatic impact on your business by itself, you can often multiply the benefits by combining them.

 See which ones pique your interest and make you want to learn more.



1. Kaizen (Continuous Improvement) 

Kaizen is a strategy where employees work together proactively to achieve regular, incremental improvements in the manufacturing process.

This strategy  is effective because it focuses the collective talents and resources of your company on creating a culture continually on the lookout for ways to eliminate waste from manufacturing processes.

 

2. 5S

 

The 5S approach emphasizes the organization of your work area. This strategy involves SORTING - eliminating that which is not needed. Once that’s done, the remaining items are SET IN ORDER. Then, you create a work area that SHINES. After that, you STANDARDIZE - writing standards for each of the above elements of the process. Finally, you SUSTAIN the strategy by regularly applying the standards.

The 5S approach eliminates waste resulting from a poorly organized work area.

 

3. Six Big Losses

Productivity inefficiency in virtually any manufacturing category can usually be traced back to 6 universally occurring loss categories.

They include breakdowns, setup/adjustments, small stops, reduced speed, startup rejects and production rejects.

The Six Big Losses approach gives you a guideline for attacking the most common causes of waste in manufacturing processes.

 

4. Overall Equipment Effectiveness (OEE)

OEE provides a framework for measuring productivity loss for a given manufacturing process. Three categories of loss are tracked: down time, slow cycles and rejects.

This lean technique establishes a baseline and gives you a means to track progress in eliminating waste from a manufacturing process. Achieving 85% OEE is a reasonable target to shoot for in the beginning. Once that’s achieved, you can focus on additional ways to elevate your results.

 

5.Machine monitoring

Machine monitoring dovetails nicely with OEE. Machine monitoring software automatically collects data from machines and uses this data to provide real-time visualizations and notifications, as well as historical analytics to help operators and management make faster and more informed decisions.

In addition to providing you with at-a-glance performance on a machine-by-machine basis, machine monitoring gives you a window onto your entire manufacturing process.

If you are utilizing secure, cloud-based manufacturing software, it also puts information at your fingertips anywhere there’s an internet connection.

Machine downtime, quality issues, and poor performance can be categorized automatically or by the operator.

The key to creating a truly lean manufacturing process is being open-minded. You may find through experimentation that a combination of lean techniques deliver the optimal result.

 


MachineMetrics can serve as the backbone to any lean manufacturing program by providing real-time manufacturing analytics and allowing you to track the positive impact your lean implementations have on your productivity and efficiency over time. 

 

Ready to get started with Machine Monitoring? Reach out to MachineMetrics today! 

Learn More

Or call us directly at 413-341-5747

 


 

Comments

Related posts

INDUSTRIAL IOT AND THE MOVE FROM PREVENTIVE TO PREDICTIVE MAINTENANCE
24Apr

INDUSTRIAL IOT AND THE MOVE FROM PREVENTIVE TO PREDICTIVE MAINTENANCE

One of the most important trends in the last few decades has been the movement toward lean manufacturing.  As companies began to review and change their operating procedures to eliminate waste, effici...

What is Industry 4.0?
17Apr

What is Industry 4.0?

  Known as the fourth industrial revolution since the 18th century, Industry 4.0 is an all-encompassing term to refer to the way computers, data and automation are evolving and coming together to chan...

Sensor Data vs PLC Data: Why Getting Deep Data Is the Right Way to Go!
09Apr

Sensor Data vs PLC Data: Why Getting Deep Data Is the Right Way to Go!

  When it comes to collecting data with industrial IoT within the world of manufacturing, it isn’t just about quantity. It’s also about the quality of the information that you are gathering from vario...

5 Myths- Manufacturing During Industry 4.0
02Apr

5 Myths- Manufacturing During Industry 4.0

The fourth industrial revolution is upon us, and as you may know, this means change. As an industry, it is imperative that manufacturers adopt new technologies and increased connectivity that will ena...

Improve Your Manufacturing Processes Using Data
27Mar

Improve Your Manufacturing Processes Using Data

Manufacturing, regardless of what tools, bits or parts the machines are producing, tends to follow decade old processes. There is an element of the 'this is how we’ve always done it and it’s worked fi...

IIoT and The Analytics Journey- MachineMetrics Presents at Hardwired NYC
20Mar

IIoT and The Analytics Journey- MachineMetrics Presents at Hardwired NYC

Bill Bither, Co-Founder and CEO of MachineMetrics, had the opportunity to speak at FirstMark’s Hardwired NYC event. In this visually stimulating presentation, he focuses on Industrial IoT- how it work...

How To Select The Right IoT Solution For Your Company
19Mar

How To Select The Right IoT Solution For Your Company

It’s always difficult for a company to choose a new software platform.  From concerns over learning curve to ROI to security to integration within an IT structure, most companies dread the process.  W...

SYNERGY RESOURCES ANNOUNCES PARTNERSHIP WITH MACHINEMETRICS
13Mar

SYNERGY RESOURCES ANNOUNCES PARTNERSHIP WITH MACHINEMETRICS

CENTRAL ISLIP, NY, March 14, 2019 – Synergy Resources, a provider of product and service solutions to the manufacturing industry, has strengthened its position in the Industry 4.0/Smart Manufacturing ...

Machine Monitoring: The Strategy to Achieve Expotential Efficiency Gains
01Mar

Machine Monitoring: The Strategy to Achieve Expotential Efficiency Gains

  Since the industrial revolution, manufacturers have been churning out goods which have bettered the livelihoods of billions of people. Machines have been fed raw material and transformed them into f...

Guest Blog: Industry 4.0 — Reinventing the Factory Stack by Robin Dechant
20Feb

Guest Blog: Industry 4.0 — Reinventing the Factory Stack by Robin Dechant

If you went to bed last night as an industrial company, you’re going to wake up today as a software and analytics company. Jeffrey Immelt, former CEO of General Electric, nails it down. Industrial com...