Lean manufacturing involves various tools and techniques for resolution of earlier discussed seven mudas, which are as
- Overproduction – Removal of overproduction involves scheduling production such that the rate of manufacturing synchronizes with the rate of customer demand (also called as Takt Time). By using a pull system to control how much is to be manufactured, as in Kanban and reducing production run setup times, so that any smaller batches needed by the customer are also be economically manufactured by applying SMED, this muda can be removed.
- Waiting – its removal needs designing of processes which result in a continuous flow and there are minimal or no buffers between steps in production. Techniques like using standardized work instructions which ensures that a consistent method and consistent times are used for each step of production also helps in removal of this muda.
- Transport – It involves designing a linear, sequential flow from raw materials to finished goods as by applying Value Stream Mapping technique and ensuring that work-in-process (WIP) is not placed into inventory. Further, avoidance of continual change of job priorities as by Theory of Constraints also helps in this muda removal.
- Excess Motion – This muda removal encompass ensuring logical organization of work areas as implemented by 5S and also considering alternate arrangements of equipment to reduce motion.
- Non-value Processing – its removal involves using Kaizen technique which compares customer requirements to manufacturing specifications and looking for simplifications to the manufacturing process.
- Needless Inventory – This muda’s removal involves various techniques of Takt Time, Kanban, SMED , JIT and Continuous Flow by bringing only raw materials as they are needed and reducing buffers between steps in production.
- Defects – It is an important muda as it is the most noticeable muda. Its removal involves designing processes to produce defects by applying the Poka-Yoke and processes to detect abnormalities for immediate correction as per Jidoka. Conducting Root Cause Analysis to single out most frequent defects and their causes. Further, creating work instructions for consistent method of manufacturing a part also helps in removal.
