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Lean Manufacturing Checklist
Value Stream Mapping
Identify the product or product family to map.
Gather a cross-functional team to participate in mapping.
Map the current state, including all steps and information flows.
Identify waste and areas for improvement in the current state.
Design a future state map addressing identified inefficiencies.
5S Implementation
Sort: Remove unnecessary items from the workplace.
Set in Order: Organize remaining items for easy access.
Shine: Clean the workspace and equipment regularly.
Standardize: Develop procedures to maintain organization.
Sustain: Create a culture of discipline and continuous improvement.
Continuous Flow
Analyze the current production process for bottlenecks.
Implement changes to balance the workload across processes.
Reduce batch sizes to facilitate a smoother flow.
Ensure all equipment is properly maintained to prevent downtime.
Train employees on the importance of maintaining continuous flow.
Setup Reduction
Identify all setup activities in the production process.
Differentiate between internal and external setup activities.
Streamline internal setup tasks to minimize downtime.
Perform as many setup tasks as possible while the machine is running.
Document and standardize the setup process for consistency.
Quality at the Source
Empower employees to stop production to address quality issues.
Implement mistake-proofing devices to prevent errors.
Conduct regular training on quality standards and procedures.
Use root cause analysis to address recurring quality problems.
Establish a culture where quality is everyone's responsibility.
