Lean manufacturing is one of the most widely utilized business improvement methodologies. There are hundreds of consultants and schools teaching lean manufacturing principles.

The problem with many courses teaching lean manufacturing is the lack of real world experience of the instructor. Many have limited experience applying the principles, nor the interpersonal skills to influence change.

Lean manufacturing is not nearly as structured as six sigma or other continuous improvement initiatives. There is no standard approach to implementation or third party certifying body such as ISO.

Lean manufacturing consists of many different “tools”. The best courses teach the lean manufacturing principles as well as how and when to use the tools.

Some companies have heard that lean manufacturing implementation will reduce their waste and costs, and decide to just start implementing. They often start using one tool at a time until the boss declares it’s done.

Worse yet, some companies find a consultant that knows 5S and little else. When the consultant leaves, the clean and organized business eventually realizes they are clean, organized, and still full of waste.

The correct approach to implementing lean manufacturing begins with an analysis of the businesses needs, opportunities, and challenges. Once these opportunities are identified, the tools are used which will solve the issues. These tools might be lean manufacturing or six sigma tools. It simply wouldn’t be prudent to limit the success of a lean initiative to exclude any tool if it was known to solve the problem at hand.

In other words, the problems identify the tools rather than the tools being force into the organization.

Some of the lean manufacturing tools are 5S (Sort-Set in Order-Shine-Standardize-Sustain), value stream mapping, kanban, takt time, continuous flow, cellular manufacturing, TPM (total productive maintenance), SMED (single minute exchange of die), OEE (overall equipment effectiveness), line balancing, standardized operations, 7 wastes (muda), error proofing, kaizen, and root cause problem solving.

There are a few tools that can and should be used with any lean manufacturing initiative. The 5S tool is a powerful workplace organization tool. This tool makes sense in any business. It would be hard to find an organization where order and organization didn’t make sense.

Root cause problem solving tools should be used in every lean manufacturing implementation. These tools vary based on the problem. Some of the more common are Cause and Effects Analysis, 5 Why Analysis, 8D method, CT trees, Process Mapping, and affinity diagrams.

Value stream mapping is another useful tool to determine where value is added and the areas of non-value added (muda). The value stream map depicts the flow of product and information on paper. Information such as inventory, distance, and bottlenecks are highlighted. Once the value stream map is completed, opportunities for improvement become obvious.

Tools such as line balancing, SMED, takt time, and OEE should be used to solve specific business opportunities. For example, SMED (single minute exchange of die) is a tool that is used to reduce machinery or process setup times. This tool is a lot more useful in businesses that run smaller order quantities and changeover often. OEE is an excellent tool to determine why a machine or process is not producing at world class levels. Once the reasons (opportunities) are known, they can be improved.

Kaizen (Japanese word meaning continuous improvement) is a very powerful improvement tool. It is basically a rapid (3-5 days) improvement method utilizing a cross-functional team to solve a business problem. A kaizen event team will use many other lean tools to help solve the problem.

Total Productive Maintenance (TPM) is an excellent tool to improve maintenance, which in turn helps improve all aspects of a manufacturing business, including OEE, setup times, downtime, costs, and profitability. TPM is based on having operators involved in the maintenance of their equipment. The operators often complete their own preventive maintenance, while other initiatives simply have them highly involved. Although TPM is a great tool, it wouldn't be as useful in a service organization without equipment.

Utilize lean manufacturing principles to identify and solve business issues and the financial impact will justify their use. If the tools are made to “fit” the organization, the result will be chaos, disruption, low morale, and financial loss.

Carl Wright is an industrial engineer, ASQ Six Sigma Black Belt, and Master Black Belt. Carl is involved with the lean manufacturing implementation organization http://www.1stcourses.com

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Labels: Machinery Tool

If you have your own shop for woodworking or anything else, then you know how important it is to have the correct machinery for your work. You need to make sure you the proper woodworking tools if you are a novice or a professional carpenter. You can have a much better experience with woodworking plans if you are properly equipped. Your work could come out much better and you will have more fun doing the job with the right tools. You have a wide variety of tools to choose from in the past few years and you can stock up on the best tools at great prices. You can get some of the best brands like Rockwell tools, Sears tools, Hitachi tools, and Rigid tools for a really good price. You’ll k now you are getting a great deal and a great tool if you go with a trusted brand.

There are a ton of different places you can buy your tools at and you will want to find somewhere that will give you a great price and give you great quality. There are lots of do it yourself type stores that sell tools, but thee aren’t always the best option for you. Sometimes they are too expensive because the shop is small and there is a large overheard which makes the owners inflate the prices. You might be able to get a good price if you go to a show where they have all the different woodworking tools on display. You can usually get a great deal on the top of the line tools. You might also find that they don’t have the selection that you require. You can have a hard time getting a great price and good quality with a large selection all at once. You can do it, but you need to know the best place to shop.

If you want a great place to find a large selection and be assured of the best price, then try shopping online for your tools. You can get a great deal if you look at a place like Rockler Woodworking. You can get the best brands, a huge selection, and super low prices. You will also be buying your products from a reputable online store, so don’t worry about where your tools are coming from.

If you want to shop in your house and if you know exactly what you want then it is fast and easy to get a great woodworking tool from the comfort of your home. You can have it delivered right to your door and they usually come quite fast. You can save a lot of time and money when you order your tools online. You can search online for the right gear and browse hundreds of online stores for an unbeatable selection. You can pay safely online with your credit card and then just sit back and relax while the new tools are shipped right to your front door. You can spend more time in your woodworking shop than out shopping!

Vince Paxton's news can be encountered on different web sites with information about hand tools and machinery. Writing for detailed writings like http://www.insidewoodworking.com ,he demonstrated his experience on topics corresponding to woodworking tools and machinery.

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Labels: Machinery Tool

If you need a machine that will improve your speed and accuracy then try a CNC machine when you are getting large jobs done or doing very repetitive tasks. You can get a used one for half the cost of a new one since most individuals wouldn’t want to spend their money on a new one. CNC equipment can be found in woodworking shops or industrial settings. Add them to your collection that includes a milling machine as well.

If you need to drill holes than consider a CNC router. Some of them can hold more than one tool too. This makes it possible to do more than one procedure at a time. This will help you cut back on the tie you spend working and help you become more accurate.

Computer Numerated Control is the full name for CNC. In the 1970’s this technology was first created. These machines are easy to run and operate after they have been initially set up. They also need to be set up correctly and programmed before they are operated.

They can be made so you can drill a hole automatically. This can be much more accurate and quicker than manual drilling. You will get more uniform results. If you have a large job that needs a lot of drilling then this can be a good choice for you. You might get more inconsistent results when you are doing manual drilling and if the operator gets tired.

If you want a good thing to cut wood with then try a CNC lathe. You can buy one that ranges from 15-40 horsepower. You will choose the lathe power you need depending on the type of wood you use. You can get a model that comes with more than one mode. You can one that is totally manual or CNC. You can rig each machine for your individual project.

If you want the best in milling technology then try a Bridgeport mill. You can find a mill in both a small shop or a large one. If you want a mill that will last forever than try a Bridgeport mill. They are very pricey and more so than most people can afford.

A CNC mill use a special type of instrument that uses a combination of robotics and computer programming. You will get great results better than anyone could ever want. These are the kind of mills that the airline companies use. The CNC decides which tool is need for an operation and changes as it goes.

Since CNC equipment is so pricey it means most people can’t afford it. If you get a used machine you may find that you can afford it. You may be able to save about half on a used machine compared to a new one.

Being really passionate about cnc machinery and woodworking tools, Greg Hansward authored different summaries in this specific area. With his detailed writings on cnc machines and tools and cnc machinery the reviewer showed his deep knowledge on the topic.

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Labels: Machinery Tool

In today’s auto shop there are many potential hazards to the fragile human body. In order to have a safe and productive work environment, there are simple steps that need to be taken in order to insure the physical safety of everyone in your automotive service shop. There are many tools and pieces of equipment in use that can potentially seriously injure someone. The first step is to take census of your auto or mechanical shop and locate machinery and tools that can be potentially hazardous. Any machine or tool that can cause a serious injury must be safeguarded. For example, a band saw is common tool in a mechanical shop and has the ability to cut off fingers and limbs. This piece of equipment needs to be safeguarded and all applicable safety features should be correctly installed. It is all too common to the plastic safety guards removed on a table saw because they are in the way of the operator. Safety cannot be sacrificed for convenience.

But remember machinery is not the only hazard, you need to be aware of in the shop. The power cords and air hoses that power equipment also presents a tripping hazard. Many auto shops have several air hoses and power cords stretched all over the place and most of them are not even being used at the moment. To combat this problem and help keep your shop floor clutter free we recommend using an air hose reel. Air hose reels are mounted on the shop walls and are usually self retracting. When a mechanic finishes working with his air tools, the air hose can be retracted and stored with a quick tug on the hose. There are similar devices for extension cords as well. Lets face it, a mechanic is much more inclined to keep his air hoses and power cords retracted if its easy and an air hose reel makes it easy. Also, spilled grease oil and oil can collect on a shop floor and produce a slipping hazard. It is inevitable that motor oil and grease will end up on the concrete floor. Most auto shops have containment spill kits that can contain the oil spill and aid in cleaning it up the minute it happens.

The next level of safety is the person. Once the auto shop is a safe and secure environment, you will need to consider the mechanics and other workers in the area. Eye protection should be worn at all times. There is almost always some type of work going on that is a potential hazard your fragile eyes. For example, grinders and needle scalers are capable of throwing debris a long way from the point of contact. People working in the same area are in just as much danger is the operator using the tool. Also, chemicals and gasoline can be splashed onto unprotected eyes causing anything from mild discomfort to blindness.

Hand and feet protection is usually fairly obvious. Most mechanics wear gloves to prevent burns and cutting while working on automobile. But gloves are also needed for a variety of other tasks as well. Do not handle chemicals and solvents with out wearing gloves and remember to remove watches and other jewelry as well. Always be aware of where you fingers are especially when lifting heavy objects. It may seem obvious but it is all too common to crush your fingers by letting a heavy object down on them. Mechanics gloves are a great choice when you need to work with small parts and tools. Mechanics gloves are light and tight fitting on your hand. This allows you to feel the parts and tools and still maintain protection. For your feet, there are advanced mechanic shoes that help you gain traction on oily floors and boots with steel toes to protect you from heavy objects.

Safety in the auto shop requires some basic common sense and attention to detail. A safe work environment is a combination of both the work area and the workers themselves. It is everyone’s responsibility to make sure the proper safety gear is worn and the rules are followed.

Jason has been in the construction equipment and industrial sales business for over 10 years. He owns and operates Red Hill Supply to better serve the automotive and industrial industries. - Automotive Tools

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Labels: Machinery Tool