Which Lean manufacturing tools provide real-time visibility into your production performance?

Eu considero duas ferramentas como as mais importantes para avalia??o em tempo real a produ??o; sistema andom e kanban. Hoje existe disponível no mercado sistemas eletr?nicos que computam a produ??o, capturam as paradas, comparam com padr?o, disparam alertas automaticamente, além da tradicional gest?o visual e alerta sonoro nas paradas da máquina. Esse tipo de sistema agiliza a identifica??o de problemas e permite o escalonamento imediato aos times de suporte. O outro s?o os quadros kanban que permitem a gest?o visual dos gargalos de produ??o. Aplicando esses sistemas você terá ferramentas muito fortes para gest?o da produ??o.

Some Lean manufacturing tools offer real-time views into production performance. These include Andon Systems, Production Dashboards, Overall Equipment Effectiveness (OEE) Software, Value Stream Mapping (VSM), Kanban Systems, and Continuous Improvement (Kaizen) Boards. They help teams monitor progress and identify areas for improvement as they happen.

1) OEE - Overall Equipment Effectiveness 2) KANBAN Boards 3) Value Stream Mapping 4) Fish Bone Analysis 5) Kaizen 6) MUDA 7) 7 QC Tools

Lean Manufacturing tools that provide real-time visibility into production performance include IIoT technology, which connects factory assets for deep insights, and advanced monitoring and analytics platforms. These allow tracking of production rates, machine conditions, and labor utilization. Visual tools like Kanban boards, 5S boards, and Balanced Scorecards also facilitate real-time communication and process streamlining in lean manufacturing operations.

Andon Systems: visual alerts for production issues, ensuring real-time visibility into performance and facilitating rapid response. Overall Equipment Effectiveness (OEE) Software: Monitors equipment efficiency, availability, & quality in real-time, enabling identification of bottlenecks and opportunities for improvement. Manufacturing Execution Systems (MES): Integrate data from various production processes, providing real-time insights into performance metrics like cycle times & downtime. Digital Dashboards: Display key performance indicators (KPIs) in real-time. Radio-Frequency Identification (RFID) Systems: Track inventory movement & production stages in real-time, enhancing visibility into material flow & work-in-progress status.

Kanban board is the customizable tool able to plan and shedule a business process in a pure Pull way. It is able to show: workloads per business unit, delays, priorities, queues, constraint and it is VISUAL

Kanban was originally developed by Toyota to streamline manufacturing processes. A Kanban Board, resembles a whiteboard divided into vertical lanes. Each lane signifies a workflow stage, progressing from "To Do" on the left to "Doing" and "Done" on the right. Work items transition from left to right, beginning from the far left lane and culminating in completion at the far right. Beyond illustrating workflow stages, Kanban boards provide insights into process policies and work-in-process (WIP) limits. Modern Kanban Boards incorporate digital enhancements which facilitates real-time updates, remote accessibility, and integration with other systems, thereby enhancing visibility, collaboration, and productivity in manufacturing processes.

Kanban systems can integrate with Internet of Things (IoT) devices installed on machinery and equipment. These IoT sensors collect data on machine performance, production output, and material consumption, which is then fed into the digital Kanban system. This integration provides a comprehensive view of production activities and enables proactive identification of issues or bottlenecks. Digital Kanban systems can integrate seamlessly with Manufacturing Execution Systems (MES) and Enterprise Resource Planning (ERP) systems. This integration ensures data consistency and facilitates information sharing across different departments and functions, enabling more informed decision-making and resource planning.

Kanban is a Lean manufacturing technique that uses visual cues to manage inventory levels and production flow. It originated from the Toyota Production System and is now widely used in various industries to improve efficiency and reduce waste. Kanban uses visual cards or signals to represent units of work or inventory. Each card typically contains information such as part number, quantity, and location. Kanban helps manage inventory levels by setting limits on the number of Kanban cards allowed for each item. Kanban also helps manage the flow of work in the production process. Each Kanban card represents a specific task or item to be produced, and the movement of cards through the system indicates the progress of work.

Os quadros de Kanban s?o vitais para qualquer indústria! é possível otimizar os processos por meio da gest?o visual de um quadro de Kanban e, inclusive, existem ferramentas digitais que permitem a elabora??o de um quadro de Kanban online, que pode ser acessado e atualizado de qualquer lugar. Ainda assim, cards físicos (de papel ou outro material mais resistentes) s?o a escolha mais adequada se o perfil dos usuários n?o for voltado às tecnologias digitais.

Value stream mapping (VSM) is a lean manufacturing tool that visualizes series of steps required to deliver a product or service to the end user. It is also known as material- and information-flow mapping. Value stream maps can be created for every individual product and service for every type of business. Using the principles of lean manufacturing, value stream mapping creates value for customers while optimizing resources and reducing waste and inefficiencies.

Traditional VSM involves mapping out the entire production process on a physical diagram. In Industry 4.0, this process can be digitized using software tools or platforms. This enables real-time updating of process maps and easy sharing of information across teams, enabling stakeholders to access up-to-date production data instantaneously. VSM can be integrated with Internet of Things (IoT) devices installed throughout the production line. These IoT sensors collect data on various aspects of production, such as machine performance, cycle times, and material flow. Here, stakeholders gain insights into the current state of the production process and can identify bottlenecks or inefficiencies as they occur.

O MFV é uma ferramenta estratégica, que deve ser feita antes de qualquer execu??o de um projeto Lean (etapa P do ciclo PDCA, ou M no DMAIC). Com essa ferramenta, é possível identificar os gargalos do processo de maneira rápida e ter uma vis?o que muitas vezes contrasta com a opini?o de quem observa o Gemba sem uma análise quantitativa.

Digital Takt time systems often include visualization tools and reporting capabilities that provide stakeholders with clear insights into production performance. Takt time calculations can be automated using digital tools and software. These tools can integrate with production systems to gather real-time data on customer demand, available production time, and the number of products to be produced. By comparing actual production rates to the Takt time, stakeholders can quickly identify deviations and take corrective actions to address inefficiencies or bottlenecks as they occur.

OEE is the most important tool for a capital intensive company. It helps to monitor downtimes and to brutally prioritize where to act in order to improve. Then PDCA follows but OEE (just like VSM for supply chain) is fundamental and all manufacturing people should be trained on this.

I have been using the Prodwin system in serial production line and I'm impressed with the outcomes. After implementing it, we managed to boost productivity by more than 20%. The system integration was smooth, and real-time insights into OEE allowed us to make quick and effective adjustments. I highly recommend it to anyone looking to improve efficiency and quality in production!

Setting up an Overall Equipment Effectiveness (OEE) tool for manufacturing involves several EZ steps. Firstly, define the metrics you want to track: Availability, Performance, and Quality. Next, select appropriate software with features like real-time monitoring and customizable dashboards. Then, implement data collection methods to gather information on machine uptime, downtime, production rates, and product quality. With this data, calculate OEE scores using the formula OEE = Availability × Performance × Quality. Regularly analyze results to identify improvement areas, such as equipment breakdowns or low productivity. Use these insights to implement targeted improvements, like preventive maintenance or optimized production schedules.

Muitas empresas têm dificuldades na coleta de dados para o OEE. Automatizar a coleta em processos, principalmente os manuais, é um desafio. No entanto, a precis?o gerada possibitará a visualiza??o em tempo real desse indicador. Um amigo especialista em automa??o desenvolveu a partir dessa premissa uma maneira de coletar automaticamente os dados, até dos processos 100% manuais. Me chame no meu perfil para descobrir essa solu??o.

OEE it′s one of the higher importance to keep in control performance however the real time measurement using additional tools like online OEE control and Mfg 4,0 it's in my opinion most quick response at any concern in real time, QRQC concept applying in OEE and all SQDC concepts

Learn yourself some IoT pronto. You're already about 15 years behind schedule. That's what truly is real time. Sadly, so many mfg companies don't care.

Example: P&G has achieved operational excellence through its Integrated Work Systems (IWS), guided by two core principles: a) the pursuit of zero defects and losses, and b) a commitment to 100% Total Employee Ownership (TEO). Through a culture of continuous improvement, P&G has seamlessly integrated Digital Lean Sigma practices into its manufacturing operations. Leveraging data analytics, automation, and machine learning technologies, they've optimized their supply chain, minimizing waste, and elevating customer satisfaction. Thus, P&G's success lies in its dedication to continuous improvement, supported by the principles of IWS and the strategic adoption of Lean and digital tools, enabling P&G to excel in the consumer goods industry.

Different processes need to be monitored at different frequency, it completely depends on the process and its criticality. DWM boards provide a good insight into the process on a daily basis. KPI monitoring, MP-CP relation, control charts help in identifying any significant change in the process. With the advancement of technology, IOT devices installed on equipment's provide real time data of their critical parameter every second. Since it involves certain cost, it is advised to use such devices for critical process only. Thus DWM boards can be used for daily monitoring while IOT devices can be used for more precise and short interval data gathering and analysis.

My suggestion is to create a control chart presenting the evolution of your project. This way it’s possible to see how is the production before and after the implementation of the improvements. If possible, connect with M.E.S. To get the on line evaluation of the equipment and present the improvements during time.