Why does tidiness in the workplace matter?
5S is a method of workplace organisation that includes: Selection, Systematics, Cleaning, Standardisation and Self-Discipline. It ensures that every tool and material has its place, increasing efficiency and reducing waste (Muda).
Example: shadow board - the missing tool can be seen immediately.
How does Poka-Yoke work?
Poka-Yoke is a system for preventing errors by designing a process or tool in such a way that a mistake is impossible to make or becomes immediately apparent.
Example: the SIM card only fits in one place in the phone.
What is Andon?
Andon is a visual system for signalling problems, usually in the form of lights or screens above the workstation. It allows you to quickly spot a disturbance and call for support.
Example: A green light means normal operation, a red light means stoppage and the need for intervention.
What is Obeya used for?
Obeya (Japanese for „big room”) is a space for project and strategy management. Objectives, indicators and status of activities are presented in one place, which promotes teamwork and transparency.
Example: project room with KPI boards and sprint plans.
How does Kanban work?
Kanban o a method of managing the flow of work and material with the aim of producing exactly what is needed - when it is needed - in the quantity that is needed.
Example: On the production line, emptying a container of components automatically triggers a Kanban signal for refilling it. Material is delivered exactly when and in the quantity needed - without creating stockpiles.
Kanban is not synonymous with a pull system - it is a practical tool that helps to introduce and maintain the work of pull logic in day-to-day operations....
What is the Pull System?
Pull The system is an approach where work only starts when there is a specific demand from the next stage of the process. It is the opposite of „pushing” products into a warehouse.
Example: a new batch is created only after the previous one has been used up.
What is Heijunka about?
Heijunka is a Lean method of aligning (levelling) production so that different products are produced in a stable, repeatable rhythm over time, instead of producing them in batches. Its aim is to reduce fluctuations, overloads and downtime, leading to smoother flow, less inventory and greater process predictability.
Example: production of 200 units per day instead of 1,000 on Monday and 0 on Tuesday.
Why is SMED so important?
SMED methodology (Single Minute Exchange of Die) is a method of rapid machine changeover - reducing set-up times to less than 10 minutes. It allows you to produce smaller batches and respond more quickly to changes in demand.
Example: mould changeover time reduced from 60 to 8 minutes.
Summary - Lean organisation and flow
- 5S and Poka-Yokeensure order and quality.
- Andon and Obeyasupport communication and rapid response to problems.
- Kanban, Pull, Heijunka and SMEDenable a smooth, flexible workflow.
