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lean-tool.com

Welcome to Lean-Tool.com
We provide tools for lean manufacturing / Toyota Production System
Easy,Simple, and Powerful


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Tool for Lean
Make Your improvement faster

Product


Get Powerful Lean Software Without the High Cost or Complexity
The familiar Excel interface reduces processing time and makes it a viable option for anyone

If you often create standardized work and must to analyze it,
such as Standardized Work Analyze Tool, Production Capacity Sheet, Yamazumi Chart


If you are familiar with the Toyota Production System / Lean,
It is time to use tools for lean from Lean-Tool.com

"Standardized work is one of the most powerful tool in Lean / Toyota Production System.
Standardized Work Containing the current best practice, standardized work forms the baseline for Kaizen or continuous improvement. As the standard is improved, the new standard becomes the baseline for further improvements.
Improving standardized work is a never-ending process."


First step to KAIZEN (improvement).
Standardized Work is the basic foundation for improvement (KAIZEN) and to evaluate and find MUDA, MURA, & MURI.
There will be no improvement without standardized work.

EASY to use with Ms.Excel Format,

With VBA (Visual Basic For Applications) programmed MS-Excel files,don't require installation, easy to use
Don't forget to enable macros when opening the files.

SIMPLE Format, you can edit for your own template,
POWERFUL, with many feature inside

Many features inside such as stopwatch function,
change your notebook to a stopwatch, observe cycle time and input automatically in Form

Our Tools :

Stopwatch 100 Laps Cycle
Stopwatch 100 Laps Cycle
Standardized Work Combination Table Macro
Standardized Work Combination Table Macro
Standardized Work Analyze Tool (SWAT)
Standardized Work Analyze Tool (SWAT)
Standardized Work Analyze Tool+Video Capture
Standardized Work Analyze Tool+Video Capture
heijunka generator
Heijunka Generator


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RSS About Lean
Update lean knowledge



Lean Eye Test: Seeing the Work
Creating the same product with two different methods can uncover things that can be improved, removed, and altered to make for the most efficient method possible. Instructional Designer at LEI, Masia Goodman, walks us through this process in this instructional video.
Why Lean Thinkers Should Ground Their Work in Sustainability
There's a solid case for implementing green thinking just as there's one for implementing lean thinking. The challenge, but more importantly the opportunity for business, lies in bringing them together, write Rose Heathcote and Gary Cundill.
Steady Work Shares Practical Ways to Create Quality Enterprise For All
Karen Gaudet's Steady Work is the story of a leader helping teams develop steady work to help them get through normal days just a little better and help make the worst day ever just a little bit bearable. Here's a taste of the many lean insights captured in this book.
How Dr. Martin Luther King Jr.'s Teaching Embodies Lean Thinking
What can we learn about lean thinking from Dr. Martin Luther King, Jr.? Christopher D. Chapman explains.
Exploring the Continued Relevance of Lean, A Best of Podcast
Lean offers a powerful and productive approach to today's problems, both large and small. This "best-of" podcast featuring talks with leading thinkers offers advice and insights on this productive approach.
A3 Problem Solving | A3 Root Cause Analysis

Problems are inevitable, no matter how hard we plan and what precautions we take, they will eventually creep up and bite us. Rushing in and trying to fix the problems quickly, however, rarely seems to truly make these problems go…

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The post A3 Problem Solving | A3 Root Cause Analysis first appeared on Lean Manufacturing Tools.
Lean Consulting and Support

Not every business or up and coming lean facilitator has the money to pay a consultant potentially thousands of dollars a day to come and provide the help and support that they are looking for. Nor do they necessarily want…

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The post Lean Consulting and Support first appeared on Lean Manufacturing Tools.
One on One Lean Coaching Online

One on One Support Improving your processes can be difficult if you do not know where to start, as can be implementing Lean Manufacturing Tools such as 5S or Value Stream Mapping. Our online coaching for Lean however could be…

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The post One on One Lean Coaching Online first appeared on Lean Manufacturing Tools.
Setup Reduction SMED Coaching

“Send me a video and I will help reduce your setup times” Reducing setup time is a vital part of most Lean implementations if you want to be able to reduce batch sizes and improve process efficiency. SMED as the…

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The post Setup Reduction SMED Coaching first appeared on Lean Manufacturing Tools.
Lean Process Improvement Coaching

“Send me a video of your process and I will help make it more efficient” One of the most common areas that companies are looking for when looking for any form of lean support is to improve their process efficiency.…

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The post Lean Process Improvement Coaching first appeared on Lean Manufacturing Tools.
Value Stream Mapping of a Complete Product

Profile:

Shahrukh A. Irani and Jin Zhou
Department of Industrial, Welding and Systems Engineering
The Ohio State University

Introduction:

Lean Thinking, a concept that is based on the Toyota Production System, extends continuous improvement efforts to reduce the costs of serving customer/s beyond the
physical boundaries of a manufacturing facility, by including the suppliers, distributors
and production system that support the manufacturing function [Womack and Jones,
1996]. These improvements and cost reductions are achieved by eliminating the muda
(wastes) associated with all activities performed to deliver an order to a customer. Wastes
are defined as "all activities that consume resources (add costs to the product) but
contribute zero value to the customer." According to Womack and Jones, there are five
steps for implementing Lean Thinking in an enterprise: 1) Define Value from the
perspective of the Customer, 2) Identify the Value Streams, 3) Achieve Flow, 4)
Schedule production using Pull, and 5) Seek Perfection through Continuous
Improvement. Womack and Jones define a Value Stream as "the set of all the specific
actions required to bring a specific product through the three critical management tasks of
any business: ...problem solving, ...information management, ...physical
transformation". Alternatively, Rother and Shook define a Value Stream as "all the
actions (both value-added and non-value-added) currently required to bring a product
through the main flows essential to every product" [Rother and Shook, 1999, p. 3].


Overview of Value Stream Mapping

Value Stream Mapping (VSM) is the process of mapping the material and information
flows required to coordinate the activities performed by manufacturers, suppliers and
distributors to deliver products to customers. Unlike the traditional process mapping
tools used by IE's, VSM is a mapping tool that maps not only material flows but also
information flows that signal and control the material flows. This enhanced visual
representation facilitates the identification of the value-adding steps in a Value Stream
and elimination of the non-value adding steps, or wastes (muda). Using VSM, many
OEM's and their top-tier suppliers have changed their existing facility layouts, as well as
existing systems for material handling, inventory control, purchasing and scheduling, to
reduce the total throughput times of orders and current levels of work-in-process (WIP)
inventories.

Please click here for the details:

Value Stream Mapping of a Complete Product.pdf

 

Value Network Mapping (VNM)

Visualization and Analysis of Multiple Flows in Value Stream Maps

Profile:

ZahirAbbas N. Khaswala and Shahrukh A. Irani 1
Department of Industrial, Welding and Systems Engineering
The Ohio State University

Outline of this Paper

First, the concept of Lean Thinking is introduced and reviewed. This is followed by an explanation of the basic concepts of Value Stream Mapping (VSM), with a listing of the advantages and disadvantages of VSM. Specifically, it is shown that the original VSM methodology breaks down in the case of "multiple flows in a value stream that merge" in the case of complex product BOMs. Next, the development of the proposed approach, Value Network Mapping (VNM), is explained in detail. Finally, the results from an industry project are analyzed and the potential benefits of the proposed approach are presented.

Please click here for the details:

Value Network Mapping (VNM).pdf

 

 

 

Flow of Product to Consumer
factory_img07.gif
Used with kind permission from the book:
"Mechanism of a Factory with Illustrations"
Published by Nippon Jitsugyo Publishing.
by Mitsuo Matsubayashi and Hiroshi Watabe.
Members of Waku Consulting Co. Ltd
Please click here for the web site of Waku Consulting.
Flow of Material and Information through the Factory
factory_img06.gif
Used with kind permission from the book:
"Mechanism of a Factory with Illustrations"
Published by Nippon Jitsugyo Publishing.
by Mitsuo Matsubayashi and Hiroshi Watabe.
Members of Waku Consulting Co. Ltd
Please click here for the web site of Waku Consulting.
Operation Flow of Whole Factory
factory_img05.gif
Used with kind permission from the book:
"Mechanism of a Factory with Illustrations"
Published by Nippon Jitsugyo Publishing.
by Mitsuo Matsubayashi and Hiroshi Watabe.
Members of Waku Consulting Co. Ltd
Please click here for the web site of Waku Consulting.