5S, Kaizen, Kanban, VSM and DMAIC for manufacturing excellence
Defects, Overproduction, Waiting, Non-utilized talent, Transportation, Inventory, Motion, Excess processing (DOWNTIME). Eliminating waste is the core of lean.
Sort (Seiri): remove unnecessary items. Set in Order (Seiton): everything in its place. Shine (Seiso): clean workplace. Standardize (Seiketsu): maintain standards. Sustain (Shitsuke): discipline and habit.
Kanban: visual pull system using cards/bin signals. JIT: produce only what's needed, when needed. Reduces WIP by 50-80%. Requires stable, predictable processes.
Map current state: material and information flow. Identify value-added vs non-value-added activities. Typical VA ratio in manufacturing: 5-20%. Target future state with reduced lead time.
Define: project scope, customer requirements. Measure: current process baseline, data collection plan. Analyze: root cause identification (Fishbone, 5 Whys). Improve: solution selection, pilot implementation. Control: SPC, control plan, standard work.