THE IMPACT OF WORLD-CLASS MANUFACTURING PRACTICES ON SMALL MANUFACTURERS - by
David K. Johnson

Lean Manufacturing Tools

In order to successfully implement lean manufacturing, one must first realize that there is much more to JIT and lean manufacturing than simply inventory reduction. The philosophy (continuous improvement and increased flexibility) that drives lean manufacturing is more important than the individual practices. Lean manufacturing is made up of several tools and techniques, which are used together as continuous improvement devices to identify and eliminate waste while increasing flexibility. Some of these tools and techniques include: value stream mapping, 5S workplace organization, total productive maintenance, setup reduction, kanbans and pull production methods, cellular manufacturing, visual signals, and process standardization.

Value Stream Mapping

Value stream mapping as described in the book "Learning to See", by Mike Rother and John Shook is one of the most useful lean manufacturing methodologies for identifying and eliminating waste. Visually representing the flow of material and information in a manufacturing system makes it possible to see the effects that lead times, inventory levels, cycle times, and non-value-added activities have on the system as a whole. Once a value stream map has been created, it can be used to identify problems within the manufacturing system as well as create a desired future state value stream map along with a prioritized list of improvement activities needed to reach the desired future state. This future state value stream map can then be used as a guide for the company during lean implementation.

5S Workplace Organization

Many of the problems often identified by value stream mapping can be traced back to a poorly organized work environment. Time spent looking for tools or stepping over unused clutter can hardly be classified as value added. In order to eliminate the inefficiencies that result from an unorganized workspace a methodology known as 5S has been developed. 5S stands for five Japanese words, which all begin with the letter S. These words have been translated into five English words, which have roughly the same meaning and also begin with the letter.

• Sort - sort through what is needed, then sort out what is not; “When in doubt, throw it out!”
• Straighten/Set in Order - a place for everything and everything in its place
• Shine - clean everything (equipment, tools and workplace)
• Standardize - do it the same way until a better way is discovered
• Sustain - make it a habit

5S not only improves the productivity of the companies who use it, but it also results in a cleaner, safer workplace where there is a specific location for everything and anything not needed is removed.

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Copyright © 2005. David K. Johnson. All Rights Reserved.