SUSTAINABLE

MANUFACTURING
TECHNOLOGIES
 Table of Cotents
• 1. Lean Production
• 2. The 7 Principles
• 3. The 7 Mudas
• 4. Tools
• 5. 5S System
• 6. Benefits of the 5S System
• 7. Tools for 5S
• 8. Immediate Results
• 9. References
 • Method for reduction of waste (muda)
without sacrificing productivity, but
Lean maximizing it
• Offer a set of principles and tools that
production assist the identification and elimination
of waste
 The 7 Principles

OPTIMIZE ELIMINATE WASTE DELIVER FAST

BUILT QUALITY IN

CREATE KNOWLEDGE DEFER COMMITMENT

RESPECT PEOPLE
• Tools: A comprehensive set of tools and analytical
techniques that are used to identify and solve problems

• Process and methodology: Best practices to use the tools

for giving solutions to problems

• Mindset: The need to achieve performance goals and

continuously improve
 The seven mudas
• Defects – waste that includes additional
work performed on a product or service

• Waiting – processes not being

synchronised

• Motion – Motion of equipment that

does not add value

• Inventory – unnecessary inventory of

products produced ‘just in time’

• Overproduction – producig more/faster

than required

• Overprocessing – putting more into the

product than is valued by the customer

• Transport – waste in material movement

 Tools
Bottleneck Aalysis
Adon
improve the performance
visual feedback that
in the part of the
indicates production
manufacturing process
status and alerts when
that limits the overall
assistance is needed
workload
Continuous flow
manufacuring where Gemba (The Real Place)
work smoothly flows to
work on field and interact
eliminate inventory,
with the employees
waiting time and
transport

Heijunka (Level Hoshin Kanri (Policy Jidoka (Autonomation)

Scheduling) Deployment) Just-In-Time (JIT)
base on: strategy, tactics, automate the
sequencing product rely on customer demand
and action, thus manufacturing process to
variants within the same to reduce inventory and
eliminating waste and improve quality and
process to reduce space requirements
poor communication reduce labor costs
inventory and lead times

Kaizen (Continuous OEE Overall Equipment

Improvement)
a good teamwork done
by the employees,
eliminating waste from
manufacturing processes
KPIs (Key Performance
Kanban (Pull System) Effectiveness
Indicaors)
regulating the flow of measuring the
track and encourage
goods to eliminate productivity to eliminate
processes to achieve the
overproduction waste from a
organization’s goals
manufacturing process

PDCA(Plan, Do, Check,

Poka-Yoke (Error Proofing) Standardized Work
Act) Root Cause Analysis
design error detaction eliminate waste by
establish a plan, solving the problem from
and prevention into the consistently applying the
implement the plan, early symtoms
production process best practices
verify results, do it again

Value Stream Mapping 5S System

Takt Time
map the flow of the improve workplace
production that aligns
production to expose and efficiency and eliminate
with customer demands
eliminate waste
 removing carefully routine documenting keep track of the
unnecessary organizing cleaning of what is being progress with
tools and the the work done to periodic
materials materials area, tools, further evaluations,
from a and tools and improve the communication,
workspace equipment processes and training

systematic approach for rooting out inefficiencies

5S System and improving organization
 Benefits of the 5S System
• Improved profits – reducing costs and improving quality

• More efficient workforce – ease the work by

implementing standard procedures

• Safer workplace – improved safety by keeping the

workplace organized

• Fewer defects – reduce errors and defects by making

easier to identify and solve problems

• Better communications – keeping the flow of information

for an efficiency in the manufacturing process
 Tools for 5S

1. Labeling

2. Signs

3. Shadow Boards

4. Floor Markings
 Immediate results
• Inventory stacked far out of reach
• Unused older inventory
• Boxes stacked in aisles
• Trash and debris allowed to accumulate

• Uniform bins and racking

• Labeled bin contents
• The aisle is free for safe access
• Racks are low enough that ladders are not
required to access the inventory
 Reference
1. https://leankit.com/learn/principles-for-lean-system/
2. https://www.graphicproducts.com/infographics/lean-essentials/
3. https://www.leanproduction.com/top-25-lean-tools.html
4. http://leanmanufacturingtools.org/7-wastes/
5. https://searcherp.techtarget.com/definition/lean-production