Eliminating Mudas: Transforming Lean-Manufacturing with Lean Tek

The prerequisite for introducing lean manufacturing is switching to the new logistics and establishing part flows in small containers. Productivity work on the line side can begin in parallel to this.

The use of small containers on a line employing the Lean Tek system for a Hoshin site provides the necessary compression of spaces and eliminates the most penalising mudas on a line: waiting and motion.

For logistics, the use of Lean Tek to construct trains and shopstocks sized for just the amount required reduces mudas of transport and inventory.

Lean transformation process with Lean Tek

The initial situation is a mixed line side with little diversity and generally large containers. This occupies considerable space and allows little flexibility. All the mudas are present.

Initial situation without Lean Tek

1. Rack unnecessarily oversized taking up too much space on the line.
2. Example of wasted non-value-creating space.
3. Onerous operator task.
4. Unnecessary motions.
5. Operator idleness.

Lean Tek : Step 1

The first step in using Lean Tek at a Hoshin site implementing small container logic - the new logistics - is to involve operators in the design of racks and flexible logistics systems based on small containers. This reduces the space used on the line side and therefore generates clearly identified free spaces. Introducing this step, for which the flexibility of Lean Tek is an essential tool, already considerably reduces the mudas of motion, waiting, inventory and transport.

1. New logistics
2. Small containers
3. Compression of spaces
4. “Zoning” of cleared spaces: nothing happens here - no mudas.
5. Parts within immediate reach of the operators.

Lean Tek : Step 2

The second stage in setting up a Hoshin site with Lean Tek is to make use of the cleared spaces to position components for a second, third or fourth line of products. This allows sequencing of production, assembly of different models with the means in place, still further reduction of mudas … in other words considerable gains in productivity.

1. Integration of a new model and its parts on the existing line.
2. Compressed line side, elimination of a several mudas: Flexibility of the production tool with a considerable increase in productivity.