8/28/20 - Zoro Staff
Efficiency in manufacturing[1] is the ultimate goal. The more efficient you are, the less waste you’ll produce. But how do you get to this state of efficiency? The resounding answer is to go lean. You may, however, feel that as a small manufacturer, it’s not feasible.
That’s a prevalent misconception. Any manufacturer can benefit from a lean approach. Being small works to your advantage as your size allows you to be nimble and bureaucracy won’t impact the rate of change.
Taking a lean approach to your business can help you now and in the future. What you’ll experience from going lean is simplicity. It also involves major changes to culture. If you have a go-lean initiative on your roadmap, take heed of these tips.
Tip One: Identify Downtime Issues
Downtime issues limit production. They are costly, even if they happen in short windows. By using the 8 Wastes method[2], you have a framework to reduce waste. This method focuses on eight types of waste:
- Defects
- Overproduction
- Waiting for a dependent process
- Disengaged talent
- Unnecessary transportation (product or communications)
- Inventory sitting idle
- Unnecessary motion
- Extra processing
By employing this method, you can focus on the specific challenges that can cause downtime. Removing as much waste as possible enables greater efficiency.
Tip Two: Focus on Flows (Product and Information) Supported by 5S
If you haven’t documented your product and information flows, you should. You can use a spaghetti diagram[3]. This serves as a visual tool to trace the flow lines of any item or activity.
Not documenting them is probably leading to breakdowns in communication and processes. By focusing on flows, you can use 5S methods—Sort, Set in Order, Shine, Standardize, and Sustain.
A 5S approach requires the involvement of all parties and doesn't require a substantial time investment for implementation. The benefits far outweigh the effort, resulting in higher throughput and shorter lead times.
No matter your size or the experience of your crew, you cannot assume everyone understands flows. Having 5S to support this is a top priority for going lean.
Tip Three: Build a Culture of Continuous Improvement
Having a lean and healthy culture[4] requires many components. One of those is instilling an environment of continuous improvement.
Gradual, consistent change that sustains continuous improvement is critical. It doesn’t mean you have to train staff in strict fundamentals. It does mean you need the idea of continuous improvement to be part of everything you do.
Seek out ideas about how to improve production processes. Making everyone part of the change shows that you appreciate their opinions. It can also increase employee engagement and foster a more inclusive environment.
Tip Four: Collect Performance Data and Act on It
Data collection on your production performance has great value. It can help you connect the dots when you discover inefficiencies. Measuring and tracking activity provides you with insights that can contribute to waste elimination and continuous improvement.
What kind of data should you collect? The simple answer is: everything. You want to collect data on your equipment, runs, inventory, and productivity.
Combining this data into dashboards allows many eyes to view and assess it. For example, if throughput is down, you need to investigate why. You can look at data from all these streams, and you may find that a piece of equipment is underperforming. You’ve found the root cause and can address it.
Tip Five: Create Part Families
Even though you’re small, you're likely managing a large number of parts. Without organization, this is likely a source of pain for your operations. Developing part families is the first step to getting this in order.
If you have part families, you’ll have a better approach to automated production flow. In this process, you may find it’s possible to eliminate certain parts, simplifying this element.
Part family exercises begin with grouping like parts that are similar in shape, size, material, or usage. From this, you can map the flow and ultimately create manufacturing cells on your shop floor. Establishing these cells results in better process streamlining.
Cells offer you the chance to run and test independently. In doing these runs, you can identify areas of overproduction.
Lean into Going Lean
Going lean isn’t something that happens fast. It requires you to shift some philosophies and processes. Start small, considering how you can leverage these five tips to gain greater efficiencies, reduce waste, and cut costs.
[1] https://www.zoro.com/manufacturing/
[2] https://goleansixsigma.com/8-wastes/
[3] https://asq.org/quality-resources/spaghetti-diagram
Product Compliance and Suitability
The product statements contained in this guide are intended for general informational purposes only. Such product statements do not constitute a product recommendation or representation as to the appropriateness, accuracy, completeness, correctness or currentness of the information provided. Information provided in this guide does not replace the use by you of any manufacturer instructions, technical product manual, or other professional resource or adviser available to you. Always read, understand and follow all manufacturer instructions.