| 1 - Muda caused by inappropriate processing |
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Using small front-picked containers reduces
the length of the line, saving on general expenditure,
reducing flow costs and saving time.
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| 2 - Muda caused by defects |
Defects cost the company money and time. They
require the installation of a non-productive remedial
system. Disposing of rejects is even more costly.
Eliminating defects means not producing them in
the first place !
This means creating a suitably ergonomic environment
in which components and tools are all in their
correct place and within immediate reach of production
operations. This reduces the likelihood of impact,
dropped equipment and bad workmanship.
Working with LeanTek to design customized structures
enables the volume of defects to be limited and
opens the way to a natural and evolving management
of any residual rejects.
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| 3 - Muda caused by unnecessary movement |
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Unnecessary movement and movement at the workstation
create no added value. Quite the opposite in fact: it
makes the work harder and takes up space. LeanTek’s
modular architecture allows workstations to be configured
so that components are as close as possible to the operator’s
hand.
This contributes to reducing the negative added value
generated by unnecessary movement. Operator productivity
improves and there are fewer constraints on work as
operators focus on productive tasks. |
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| 4 - Muda caused by unnecessary stock |
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Stocks of finished products, semi-finished
products and raw materials create no added value.
Quite the opposite in fact : excessive stocks
increase costs as a result of the investment required
to handle them.
The Muda that results from unnecessary stock is
linked to that caused by overproduction. Using
a LeanTek system in association with smaller,
more frequent deliveries allows companies to reduce
stocks.
This is achieved by installing dynamic supermarket-style
storage as close as possible to the line : the
stock handler can then take products directly
from the flow racks to supply the production line.
LeanTek allows stock to be sized to the strict
minimum required and allows it to evolve simply
and quickly. |
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The LeanTek contribution to eliminating this Muda
is the creation of modular supermarkets, which evolve
as stock reduces and containers develop. LeanTek flexibility
also delivers optimized work surfaces and ergonomic
working. |
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| 5 - Muda caused by waiting |
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This Muda is generated when the operator no longer
has the components required to carry out his/her task
: their hands are idle. The installation of a line-side
system like LeanTek in conjunction with small containers
removes the risk of a break in supplies.
This works through the installation of a new logistics
system based on continuous flow and regular supplies.
Operators can then concentrate on added value operations,
whilst logistics supplies components in small trains. |
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| 6 - Muda caused by transport |
Moving products from one place to another creates
no value. Quite the opposite in fact: transport
eats up space and capital.
The Lean Manufacturing method requires that logistic
circuits are as short as possible in the plant,
between the loading bay and the supermarket and
between the supermarket and the line-side.
This works through implementing a new
logistics system based on flexible trains capable
of distributing all the components required for
production to several teams in a single journey.
The flexibility delivered by LeanTek means that
wagons can be designed specifically for each component.
The implementation of this type of system cuts
transport-generated Muda by a factor of 3.
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| 7 - Muda caused by overproduction |
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The introduction of a Kanban system combats waste
from overproduction. LeanTek’s contribution is
the creation of customizable JIT supermarkets as close
to the line as possible. |
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