OPTIMIZATION TOOLS
Lean manufacturing
Waste of the Motion
LEAN MANUFACTURING – WASTE 1 | Motion
What is it?
It refers to unnecessary or excessive or non-ergonomical physical movements during the manufacturing process by worker that do not add value to the final product.
Why does it happen?
Poor ergonomic workplace layout design and inefficient workspace organization.
Operators may not be adequately trained or experienced.
Absence of 2S (Set in order).
How to identify it? ...
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Lean manufacturing
Waste of the Overproduction
LEAN MANUFACTURING - WASTE 2 | Overproduction
What is it?
Overproduction is the act of producing more than is required, or producing earlier than it is needed. It is often considered the most detrimental of the Lean Manufacturing wastes because it can hide other wastes, such as defects, excess inventory, and unnecessary processing. Understanding and eliminating overproduction is key to optimizing operations and achieving lean excellence.
How to identify it?
Recognizing the signs of overproduction is the first step towards eliminating it:
Overstocked storage areas, ...
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Lean manufacturing
Waste of the Waitings
LEAN MANUFACTURING - WASTE 3 | Waitings
What is it?
The waste of waiting occurs when workers, machines, or products are left idle while waiting for materials, information, or the completion of another process.
Possible Causes?
Process and Equipment issues:
Equipment Setup and Adjust Times.
Equipment Failures and Repairs
Maintenance Activities: Scheduled and unscheduled maintenance stoppages, ...
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Visual Factory
Andon System
OPTIMIZATION TOOLS | VISUAL FACTORY: ANDON SYSTEMS
What is an Andon System?
Andon (a Japanese word meaning "lamp") is a simple but powerful visual management tool (device) widely utilized in factories. It helps workers and supervisors know immediately when something goes wrong in production—like a machine stopping, materials shortages, or a quality problem. It uses lights, sounds, and even phone alerts to communicate these issues clearly and quickly. 🌟
How the Andon System Works?
1.- Detection & Activation.
Each production line or workstation has a small box with buttons (called an Andon box) or sensors...
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Visual Factory
Floor Marking
VISUAL FACTORY: FLOOR MARKING: COLOUR AND LINE WIDTH GUIDELINES✨
What Is Floor Marking in a Visual Factory?
Floor marking is a visual management technique used to organize space and improve safety, efficiency, and communication on the shop floor. Colored lines, zones, and labels guide the movement of people, materials, and equipment—making everything visible and easy to understand at a glance.
This document provides a practical guide for applying floor markings using colours and line widths.
Advantages of Floor Marking Systems
1. Enhanced Workplace Safety
Visually distinguishes hazardous zones and defines access to emergency....
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Quality Methodology
Poka-Yoke
POKA-YOKE: A SMART AND SIMPLE WAY TO PREVENT MISTAKES
What is Poka-Yoke?
It is a device or method that eliminates any possibility that the operator can make mistakes, due to fatigue or distraction, which implies defective products. Its key role is to ensure 100% verification before the process continues.
These mistakes can be, among others:
Product with Missing Part.
Product with Wrong Part Assembled.
Manufacturing Process Steps missed or incorrectly done.
Wrong Setup of Machines or Equipment.
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