Favourite Lean Manufacturing Tools

This entry is another request. A colleague knows that I have experience in Lean Manufacturing and has asked to write about my favourite tools that I have used. I have put together a list of my 5 favourite tools with a brief description of each.


1. Kanban - This is an inventory control system utilized in manufacturing. It can be set up to ensure inventory levels are adequate without having to rely on a work order or a schedule being made. There are different forms of Kanban that can be utilized. 

In a sub-assembly area, it can be as simple as a bin or cart system. When a bin is empty, an operator fills it. This works well when there are a lot of common parts used to manufacture sub-assemblies. The inventory levels of the bins needs to be accurately determined to ensure over production does not take place. 

In a manufacturing area, the 3 cart system works well. In this system, there is a cart being used at the assembly site, one cart ready to be used at the assembly cart and a third cart getting ready to go into the queue. When the cart is emptied at the assembly site, the carts are rotated and the process continues. Using this method gives you a quick visual of how the process is working. 

One thing to consider with this tool is it may not fit all manufacturing processes. You will need to analyze all aspects to ensure it will fit. 

2. 5S - This is probably the most popular tool utilized in the Lean Manufacturing toolbox. It is a workplace organization methodology. It is a 5 step process with each step starting with "S". This is generally the first tool companies use when tackling Lean Manufacturing. It is designed to eliminate unnecessary items at workstations and have the facility in a state of order. The process is explained below:

Sort - This is the evaluation stage. All unnecessary items are identified with red tags and removed for the area. 

Set in Order - This is the organization stage. The required items are placed in a manner that optimizes the area. This is where the shadow boards are designed.

Shine - This is the cleaning stage. A daily program is designed to ensure the workstations are cleaned. 

Standardize - Each workstation in an area needs to be set up the same. That ensures any operator can work at any station and not need training. 

Sustain - This is often the overlooked stage. This is the stage that ensures long term success. This is where the audits and presentation of the data takes place. It is critical that audits take place to ensure everyone is following the process.

3. SMED (Single Minute Exchange of Die) - This is a tool for anyone that has to perform machine set-ups or die changes. The goal is to get the die exchange down below 10 minutes. This tool forces you to analyze all aspects of machine set-up. You need to look at storage, transportation time, machine layout, operator movement and training to name a few. You need to consider everything. 

There is no defined method to this tool; there are only recommendations. There are so many differences between facilities and machines. The key is to keep the goal in mind - less than 10 minutes. This will end up saving a lot of money in a year, especially companies with a broad product mix and a lot of changeovers. 

4. Value Stream Mapping - This tool is too complex to go into detail here. This tool is used to map the current state of any process. All aspects of the process, including times, are included. This map is used to design the future state (desired state) of the process. This gives the team a clear picture of the goal. 

This tool will require training or detailed reading. There is a lot to consider when using it. If you are considering using Lean Manufacturing tools, you need to consider this one.  

5. Visual Factory - This is something that I think is valuable in any company. The term "Visual Factory" can be used to describe a lot of things. I like to use it in a few different ways. The first is presenting plant/factory information to all employees. This can be general safety info, quality numbers, sales numbers, etc. Any information the company wants to present to employees. This can be a communication board, newsletter or online format. 

The second method is to present real-time data to each process. During the manufacturing of a product, the line will display all productivity numbers. This is items such as time to build, number built, rejects, etc. This gives everyone working on that line up-to-date information about the shift. That data can even list other shift's info as well. 

The third item is clearly identifying product or process requirements. If the product is time-dependent, clearly identify the time. If the day manufactured is critical, the product could be coloured coded. The information that is critical should be clearly understood to ensure product is manufactured correctly.


I have provided a brief descriptions of the tools. There is a lot more information required before using any of these tools. I recommend you do further research and talk to someone that has knowledge of the tools you are interested in prior to trying them. Good luck and have fun.