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You're starting a new job in manufacturing. What are the essential skills you need to succeed?

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If you're starting a new job in manufacturing, you might be wondering what are the essential skills you need to succeed. Manufacturing is a dynamic and competitive industry that requires constant improvement and adaptation. One of the most widely used and effective approaches to manufacturing excellence is lean manufacturing. Lean manufacturing is a set of principles and practices that aim to eliminate waste, increase value, and optimize processes. In this article, we'll explore some of the key skills you need to master lean manufacturing and thrive in your new role.

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Hien Nguyen

Operations Excellence Director | Driving Continuous Improvement and Culture | Master Black Belt Lean Six Sigma

1 Understand the value stream

The value stream is the sequence of activities that transform raw materials into finished products that meet customer needs. It includes both the physical flow of materials and the information flow that supports it. To apply lean manufacturing, you need to understand the value stream of your product or service, and identify where there are wastes, inefficiencies, or delays. You can use tools like value stream mapping to visualize and analyze the current state of your value stream, and design a future state that eliminates or minimizes waste and maximizes value.

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Hien Nguyen

Operations Excellence Director | Driving Continuous Improvement and Culture | Master Black Belt Lean Six Sigma
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This is an essential skill to see how a manufacturing process works and know how the value added activities and non-value added activities are performed. That is how you truly understand the process, paving the way for improvements.

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Thiago Loretti

Gerente de Qualidade, Sustentabilidade e Processos | Professor Lato Sensu na Funda??o Assis Gurgacz | Pesquisador de Kaizen | Master Black Belt em Lean Six Sigma | Auditor Líder ISO 9001 e 14001
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Para ter sucesso em um novo trabalho na manufatura, é essencial possuir habilidades técnicas, interpessoais e de resolu??o de problemas. As habilidades técnicas incluem conhecimentos específicos da área de manufatura, como opera??o de máquinas, leitura de desenhos técnicos e conhecimento de processos de produ??o. Habilidades interpessoais, como comunica??o eficaz, trabalho em equipe e capacidade de colaborar com colegas de trabalho, s?o fundamentais para um ambiente de manufatura colaborativo. Além disso, habilidades de resolu??o de problemas s?o essenciais para identificar e corrigir problemas de produ??o de forma eficiente, contribuindo para a eficiência e qualidade do processo de fabrica??o.

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2 Implement the 5S method

The 5S method is a simple but powerful technique to organize your workplace and improve its efficiency and safety. The 5S stands for sort, set in order, shine, standardize, and sustain. Sort means to remove any unnecessary items from your work area and keep only what you need. Set in order means to arrange and label everything in a logical and convenient way. Shine means to clean and maintain your equipment and tools regularly. Standardize means to establish rules and procedures for how to perform your tasks and keep your work area in order. Sustain means to monitor and audit your 5S activities and make them a habit.

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Vu Truong

Supplier Quality
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Understanding the value stream is essential for organizations to identify areas of waste, inefficiency, and improvement opportunities. By mapping out the value stream, businesses can streamline processes, eliminate bottlenecks, and deliver products or services more efficiently to meet customer needs and expectations.

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3 Apply the PDCA cycle

The PDCA cycle is a four-step method to solve problems and improve processes. PDCA stands for plan, do, check, and act. Plan means to define your problem, set your goals, and develop a plan of action. Do means to execute your plan and collect data on the results. Check means to analyze your data and compare it with your goals. Act means to take corrective actions if needed, or standardize your solution if successful. The PDCA cycle is a continuous process that helps you learn from your experience and make incremental improvements.

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4 Embrace teamwork and collaboration

Lean manufacturing is not only about tools and techniques, but also about people and culture. You need to work effectively with your colleagues, managers, suppliers, and customers to achieve your common goals. You need to communicate clearly and respectfully, share your ideas and feedback, listen to others' perspectives, and support each other. You also need to embrace a culture of learning and improvement, where you are willing to admit mistakes, learn from them, and seek opportunities to grow.

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5 Adopt a customer-centric mindset

The ultimate goal of lean manufacturing is to create value for the customer. You need to understand who your customer is, what their needs and expectations are, and how you can meet or exceed them. You need to focus on delivering quality products or services that solve your customer's problems or satisfy their desires. You also need to seek feedback from your customer, and use it to improve your value proposition and customer satisfaction.

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Hien Nguyen

Operations Excellence Director | Driving Continuous Improvement and Culture | Master Black Belt Lean Six Sigma
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Based on the understanding of the value stream, you need to map what you know about the customers want and expect (customer-centric mindset) with the manufacturing activities. On this mapping, you are able to distinguish clearly the value added activities and non-value added activities. This triggers how you can redesign and/improve the process.

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6 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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You're starting a new job in manufacturing. What are the essential skills you need to succeed?

1

2

3

4

5

6

1 Understand the value stream

2 Implement the 5S method

3 Apply the PDCA cycle

4 Embrace teamwork and collaboration

5 Adopt a customer-centric mindset

6 Here’s what else to consider

Lean Manufacturing

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You're starting a new job in manufacturing. What are the essential skills you need to succeed?

1

2

3

4

5

6

1 Understand the value stream

2 Implement the 5S method

3 Apply the PDCA cycle

4 Embrace teamwork and collaboration

5 Adopt a customer-centric mindset

6 Here’s what else to consider

Lean Manufacturing

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