Lean Manufacturing Tool Kit

Lean Manufacturing has been evolving for over 50 years as the Toyota Production System.  There are many Lean manufacturing and kaizen tools that are used to enable rapid and smooth process flow.  These well-developed Lean Manufacturing tools are used to make improvements on a team-based Kaizen Event and also on a a daily basis by everyone.

Here are just a few samples of Lean Manufacturing tools and kaizen principles you can use.

Kaizen Newspaper
The Kaizen Newspaper is one of the most important tools used during and following the Gemba Kaizen Workshop week.  The Kaizen Newspaper is more than a 30-day action item list.  The Kaizen Newspaper is:

• A training tool to keep people thinking in terms of the 7 Wastes
• A means of communication between shop floor and management
• A tool of Visual Management of the kaizen process itself
• Sample Kaizen Newspaper

Gemba Kaizen Fundamentals
The following are visual aids to introduce and reinforce the basic principles of Kaizen and Lean manufacturing.

• Kaizen
• Definition of Lean
• 7 Wastes of Production
• 5S & Workplace Organization
• 5S Radar Chart
• Just in Time Production
• Takt Time Calculation
• Standard Worksheet

Gemba Kaizen Workshop Preparation
Running effective Gemba Kaizen Workshops is no different than manufacturing a product - there is a flow. As in manufacturing, a smooth flow is realized only when everything goes according to plan. These tools help to plan, prepare, and put the right resources in place before doing kaizen.

• No Layoffs Commitment
• Team Member Selection
• Kaizen Material Preparation
• Workshop Checklist

Kaizen Workshop Forms
The following are standard forms used during a Gemba Kaizen Workshop.

 

5S Evaluation

• Part 1
• Part 2
• Part 3

Kaizen Before and After
Kaizen Newspaper
Parts - Process Matrix
Process at a Glance

Safety Evaluation

• Part 1
• Part 2
• Part 3
• Part 4
• Part 5

Set-Up Observation
Set-Up SWCS
Set-Up SWCS Example
Spaghetti Diagram
Standard Work Combination Sheet
Table of Production by Capacity (Process Capacity Table)
Target Progress Report
Time Motion Study

The 5S Action Pack complete with training presentation, printable workbook files, a 5S poster and packs of Red Tags available for purchase now.

Value Stream Mapping made easier through iGrafx FlowCharter software  solutions.  See demo video here.

Use the mini-poster value packs (10, 50, 100 and 500 count) to spread awareness and knowledge of 5S, the 7 Wastes, and 10 Commandments of Improvement throughout your organization!