Submitted By,

Jarzid Alam
Alomgir Badsha
Saif Mahabub
Introduction!
 5S
What is 5S?
KPIs (Key Performance Indicators)
What are KPIs?
 Andon
What is Andon?

• Visual feedback system for the plant

floor that indicates production status,
alerts when assistance is needed, and
empowers operators to stop the
production process.

How does Andon help?

• Acts as a real-time communication
tool for the plant floor that brings
immediate attention to problems
as they occur – so they can be
instantly addressed.
 Bottleneck Analysis
What is Bottleneck Analysis?

• Identify which part of the

manufacturing process limits the
overall throughput and improve the
performance of that part of the
process.

How does Bottleneck Analysis help?

• Improves throughput by
strengthening the weakest link in the
manufacturing process.
 Continuous Flow
What is Continuous Flow?

• Manufacturing where work-in-

process smoothly flows through
production with minimal (or no)
buffers between steps of the
manufacturing process.

How does Continuous Flow help?

• Eliminates many forms of waste
(e.g. inventory, waiting time, and
transport).
Gemba (The Real Place)
What is Gemba?

• A philosophy that reminds us to get

out of our offices and spend time on
the plant floor – the place where real
action occurs.

How does Gemba help?

• Promotes a deep and thorough
understanding of real-world
manufacturing issues – by first-hand
observation and by talking with plant
floor employees.
 Heijunka (Level Scheduling)
What is Heijunka?

• A form of production scheduling that

purposely manufactures in much
smaller batches by sequencing
(mixing) product variants within the
same process.

How does Heijunka help?

• Reduces lead times (since each
product or variant is manufactured
more frequently) and inventory
(since batches are smaller).
 Hoshin Kanri (Policy Deployment)
What is Hoshin Kanri?

• Align the goals of the company

(Strategy), with the plans of middle
management (Tactics) and the work
performed on the plant floor
(Action).

How does Hoshin Kanri help?

• Ensures that progress towards
strategic goals is consistent and
thorough – eliminating the waste
that comes from poor
communication and inconsistent
direction.
 Jidoka (Autonomation)
What is Jidoka?

• Design equipment to partially

automate the manufacturing process
(partial automation is typically much
less expensive than full automation)
and to automatically stop when
defects are detected.

How does Jidoka help?

• After Jidoka, workers can frequently
monitor multiple stations (reducing
labor costs) and many quality issues
can be detected immediately
(improving quality).
Kaizen (Continuous Improvement)
What is Kaizen?
Kanban (Pull System)
What is Kanban?
KPIs (Key Performance Indicators)
What are KPIs?
Muda (Waste)
What is Muda?
PDCA (Plan, Do, Check, Act)
What is PDCA?
Overall Equipment Effectiveness (OEE)
What is Overall Equipment Effectiveness?

• Framework for measuring

productivity loss for a given
manufacturing process. Three
categories of loss are tracked:
• Availability (e.g. downtime)
• Performance (e.g. slow cycles)
• Quality (e.g. rejects)

How does Overall Equipment

Effectiveness help?
• Provides a benchmark/baseline and a
means to track progress in
eliminating waste from a
manufacturing process. 100% OEE
means perfect production
(manufacturing only good parts, as
fast as possible, with no downtime).
Poka-Yoke (Error Proofing)
What is Poka-Yoke?

Design error detection and

prevention into production
processes with the goal of
achieving zero defects.

How does Poka-Yoke help?

• It is difficult (and expensive) to
find all defects through
inspection, and correcting
defects typically gets
significantly more expensive at
each.
 Root Cause Analysis
Cause AnalysisWhat is Root ?

A problem solving methodology that

focuses on resolving the underlying
problem instead of applying quick
fixes that only treat immediate
symptoms of the problem. A
common approach is to ask why five
times – each time moving a step
closer to discovering the true
underlying problem.

How does Root Cause Analysis help?

• Helps to ensure that a problem is
truly eliminated by applying
corrective action to the “root
cause” of the problem.
Single-Minute Exchange of Dies (SMED)
What is Single-Minute Exchange of Dies?

• Reduce setup (changeover) time to

less than 10 minutes. Techniques
include:
• Convert setup steps to be external
(performed while the process is
running)
• Simplify internal setup (e.g. replace
bolts with knobs and levers)
• Eliminate non-essential operations
• Create Standardized
Work instructions

How does Single-Minute Exchange of

Dies help?
• Enables manufacturing in smaller
lots, reduces inventory, and improves
customer responsiveness.
 SMART Goals
What are SMART Goals?

Goals that are: Specific,

Measurable, Attainable, Relevant,
and Time-Specific.

How do SMART Goals help?

• Helps to ensure that goals are
effective.
 Takt Time
What is Takt Time?

The pace of production (e.g.

manufacturing one piece every 34
seconds) that aligns production with
customer demand. Calculated as Planned
Production Time / Customer Demand.

How does Takt Time help?

• Provides a simple, consistent and
intuitive method of pacing
production. Is easily extended to
provide an efficiency goal for the
plant floor (Actual Pieces / Target
Pieces).
Value Stream Mapping
What is Value Stream Mapping?

A tool used to visually map the flow of

production. Shows the current and
future state of processes in a way that
highlights opportunities for
improvement.

How does Value Stream Mapping help?

• Exposes waste in the current
processes and provides a roadmap
for improvement through the future
state.