Spaghetti Plot – Visualize the process inefficiencies caused by layout

Spaghetti Plot is a method of viewing observations to visualize possible flows through systems. Flows depicted in this way appear like noodles, hence the coining of this term Spaghetti Plot. This method of statistics was first used to track routing through factories. Visualizing flow in this way can cut inefficiency within the flow of a system. In regards to animal populations and weather buoys drifting…

Single-Minute Exchange of Die (SMED)

Single-Minute Exchange of Die (SMED) is one of the many lean production methods for reducing waste in a manufacturing process. It provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product. This rapid changeover is key to reducing production lot sizes and thereby improving flow (Mura). The phrase “single minute” does not mean that…

Seven wastes in Service industry

The original seven wastes (Muda (Japanese term)) were defined by Taiichi Ohno, the father of the Toyota Production System. These wastes have been often redefined to better fit new organisations, industries, or external pressures. The effect of the waste is visible in a manufacturing industry. Adopting the Seven wastes in Service industry  is really difficult as the flow and the loss due to these wastes is…

Identification of Six Sigma Projects – Idea Generation

We had some guidance on the six Sigma Projects. Now let us focus on identification of Six Sigma Projects. Six Sigma is accomplished one project at a time. Identification of Six Sigma Projects shall aim at breakthrough Improvements and not simple goals. The billion of dollars saved by companies around the world is the cumulative effect of properly selecting and defining business issues that can…

What is Value Stream Mapping (VSM)

Value Stream Mapping (VSM) is a Lean tool, to visualize the various steps and their contribution to the overall process. Value When a product or service has been perceived or appraised to fulfill a need or desire–as defined by the customer–the product or service may be said to have value or worth. Components of value may include quality, utility, functionality, capacity, aesthetics, timeliness or availability, price,…

What is Rapid Improvement Event (RIE)

Rapid Improvement Event (RIE) is a 4-5 day process utilizing a team based methodology to apply the lean tools for seeing waste and making immediate improvement. The focus in a Rapid Improvement event is to work on the set up time or the Changeover time. Set-up Time Work required to change over a machine or process from one item or operation to the next item or…

Cellularization or Cellular Manufacturing

In lean Manufacturing, Cellurization or Cellular Manufacturing is used to great affect. These are the Quality control tools used for cycle time reduction and set up time reduction. Cellular Manufacturing An approach in which manufacturing work centers (cells) have the total capabilities needed to produce an item or group of similar items; contrasts to setting up work centers on the basis of similar equipment or…