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How can Lean Manufacturing professionals choose the right tool for a problem?

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Lean Manufacturing is a philosophy and a set of practices that aim to eliminate waste, improve quality, and increase customer value. As a Lean Manufacturing professional, you may encounter various problems that require different tools to solve them. But how do you choose the right tool for a problem? In this article, we will guide you through some steps and criteria that can help you make a better decision.

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Uriel Morales Rodríguez

Operational Excellence Manager | Lean Six Sigma Leader | Master Black Belt | Continuous Improvement Manager | TPS…
Daniel Cuevas

Operational Excellence & Project Management @ Novartis | Lean Six Sigma Black Belt

1 Identify the problem

The first step is to identify the problem clearly and accurately. You need to understand the root cause, the impact, and the scope of the problem. You can use tools such as the 5 Whys, the Fishbone Diagram, or the Pareto Chart to help you with this step. These tools can help you break down the problem into smaller and more manageable parts, and prioritize the most important ones.

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Daniel Cuevas

Operational Excellence & Project Management @ Novartis | Lean Six Sigma Black Belt
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Many leaders I have met have gone to a seminar or webinar, learned the wonders of a SMED and wanted to apply it from one day to the next. The result? Normally not very positive. The tools are important, but they must be at the service of the strategy and methodology. Therefore, in my opinion, you should not focus on the tooling, but rather on what you want to achieve.

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2 Define the goal

The next step is to define the goal or the desired outcome of solving the problem. You need to have a clear and measurable objective that aligns with your customer's needs and expectations. You can use tools such as the SMART Criteria, the KPIs, or the Balanced Scorecard to help you with this step. These tools can help you set specific, measurable, achievable, relevant, and time-bound goals, and monitor your progress and performance.

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3 Select the tool

The third step is to select the tool that best suits your problem and your goal. You need to consider several factors, such as the complexity, the urgency, the resources, and the feasibility of the problem. You also need to evaluate the benefits, the costs, and the risks of each tool. You can use tools such as the Decision Matrix, the SWOT Analysis, or the Cost-Benefit Analysis to help you with this step. These tools can help you compare and contrast different options, and weigh their pros and cons.

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4 Apply the tool

The fourth step is to apply the tool that you have chosen to solve the problem. You need to follow the instructions, the guidelines, and the best practices of the tool. You also need to communicate, collaborate, and coordinate with your team and your stakeholders. You can use tools such as the PDCA Cycle, the A3 Report, or the Standard Work to help you with this step. These tools can help you plan, do, check, and act on your solution, and document and share your results and learnings.

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5 Evaluate the results

The fifth step is to evaluate the results of your solution and the effectiveness of your tool. You need to measure and analyze the outcomes, the outputs, and the impacts of your solution. You also need to compare and contrast them with your initial goals and expectations. You can use tools such as the Control Chart, the Run Chart, or the Histogram to help you with this step. These tools can help you visualize and interpret your data, and identify any trends, patterns, or variations.

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6 Learn and improve

The final step is to learn and improve from your experience and feedback. You need to reflect and review your process, your performance, and your problems. You also need to identify and implement any improvements, changes, or corrections that are needed. You can use tools such as the Kaizen, the Gemba Walk, or the 5S to help you with this step. These tools can help you continuously monitor, assess, and enhance your work environment, your workflow, and your value.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Uriel Morales Rodríguez

Operational Excellence Manager | Lean Six Sigma Leader | Master Black Belt | Continuous Improvement Manager | TPS Practitioner | Data Driven | Family Sciences | I help you to optimize your operations and reduce costs
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La más importante es ?Conocer y entender las herramientas! Como mínimo haber participado ayudando en la implementación de una herramienta, porque ya por leer sobre una herramienta creemos que ya podemos implementar sin tener experiencia real en su uso, lo cuál puede hacer que escojamos la herramienta equivocada o menos efectiva

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How can Lean Manufacturing professionals choose the right tool for a problem?

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1 Identify the problem

2 Define the goal

3 Select the tool

4 Apply the tool

5 Evaluate the results

6 Learn and improve

7 Here’s what else to consider

Lean Manufacturing

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How can Lean Manufacturing professionals choose the right tool for a problem?

1

2

3

4

5

6

7

1 Identify the problem

2 Define the goal

3 Select the tool

4 Apply the tool

5 Evaluate the results

6 Learn and improve

7 Here’s what else to consider

Lean Manufacturing

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