Here's how you can streamline work processes to boost efficiency as a manufacturing engineer.

Para aumentar a eficiência dos processos utilizando os princípios Lean, é essencial seguir algumas diretrizes. Primeiro, identifique e elimine os desperdícios (Muda) avaliando os processos para encontrar atividades que n?o agreguem valor ao produto final. Em seguida, implemente o Fluxo Contínuo para minimizar interrup??es, adote o Sistema Puxado para produzir conforme a demanda, e melhore continuamente (Kaizen) os processos, padronizando as atividades. N?o se esque?a de usar o Just-in-Time (JIT) para sincronizar a produ??o com as necessidades do mercado. Ao aplicar esses princípios, os processos ser?o simplificados, resultando em maior eficiência e produtividade na manufatura.

Lean principles are foundational to optimizing manufacturing processes by eliminating waste, improving flow, and maximizing value to the customer. By focusing on continuous improvement (Kaizen), you can streamline operations by identifying and removing non-value-added activities. Tools like 5S, value stream mapping, and Just-In-Time (JIT) production help create a more efficient, organized, and responsive manufacturing environment, driving productivity and reducing costs

Para eliminar desperdicios y por supuesto que las 5s contribuyen en gran medida a la mejora de los procesos y por consecuencia mejor calidad en los productos.

In the pursuit of efficiency and competitiveness, lean manufacturing principles provide a roadmap for engineers to follow. By embracing the core tenets of lean thinking and implementing strategies for waste reduction and process optimization, engineers can unlock new levels of productivity and effectiveness in manufacturing operations. As the engineering and manufacturing services landscape continues to evolve, the principles of lean manufacturing remain as relevant and impactful as ever, guiding engineers toward excellence and sustainable success.

Si bien es la metodología da los fundamentos de la transformación cultural, sin sistemas de visualización de desperdicios y el entrenamiento continuo en esta cultura representa grandes desafíos para cualquier industria.

Uma das principais métricas do Lean Manufacturing é o mapeamento dos processos através do uso do VSM (mapa de valor), com essa ferramenta conseguimos visualizar de forma clara e precisa todo o fluxo de um processo e/ou um produto, os gargalos para ent?o atuar através de Kaizen para problemas mais simples ou projeto de melhoria com ferramentas Lean Seis Sigma para temas mais complexos.

Process mapping is a critical tool for visualizing and analyzing the steps involved in manufacturing processes. By creating detailed maps of workflows, you can identify bottlenecks, redundancies, and inefficiencies. This clarity enables you to streamline operations by redesigning processes to be more straightforward and effective. It also aids in communicating complex procedures to team members, ensuring everyone is aligned on process improvements.

El VSM facilita la visualización para la metodología lean, más aya de lo bonito que se pueda ver, lo ideal es tener claros los indicadores que serán claves en los objetivos de rendimiento (OKR), dar seguimiento a las desviaciones mediante ACR cuando la causa raíz no es conocida y la medición de la eficacia de los planes de acción mediante checkpoint futuros.

Automation technology is revolutionizing manufacturing by enabling faster, more precise, and consistent production. By integrating advanced robotics, AI, and IoT into your processes, you can reduce manual labor, minimize errors, and increase throughput. Automation not only boosts efficiency but also allows for scalable production and adaptability to market demands. The key is to identify repetitive tasks that can be automated, freeing up human resources for more strategic activities.

Data analytics is essential for informed decision-making in manufacturing. By leveraging real-time data from production lines, you can gain insights into process performance, equipment efficiency, and product quality. Advanced analytics tools help identify patterns, predict maintenance needs, and optimize operations. Using data-driven strategies, you can continuously refine processes, reduce downtime, and enhance overall efficiency.

Perfecto el tema de la ciencia de datos, pero lo que he observado en diversas industrias que los datos no tienen foco en contestar preguntas como ?para qué mido esto? ?Que espero lograr midiendo esto? ?Cuáles son los planes de contingencia ante desviaciones predictivas?. Si, perfecto tomar decisiones con datos, pero ?realmente tengo los datos que me sirven?. Es como el tablero de un automóvil, te indica todo lo que necesitas supuestamente, no obstante el vehículo falla jajaja, y luego tienes a qué conectar un scanner para saber que es lo que ocurre. Es por esto que el enfoque de los datos no basta con simples KPI, o gráficos que me muestra “lo que ya se” y deben ser enfocados en alertas tempranas.

Investing in robust training programs is crucial for equipping your team with the skills needed to operate efficiently in a modern manufacturing environment. Well-trained employees are more competent in using advanced machinery, adhering to quality standards, and implementing lean methodologies. Continuous training ensures your workforce is adaptable to new technologies and processes, reducing errors and enhancing productivity.

Otro punto que uno puede observar en todas las industrias las famosas capacitaciones que aveces son solo una prueba en algún portal institucional, lo que falla es que no miden las actitudes y capacidad de resolución en el proceso y los líderes no dan coach al equipo por qué están todo el día con meet, así que por papel el personal está capacitado y la confirmación de rol no la aplican como corresponde. La transformación cultural en mejora continua mide actitud y comportamiento de las personas más aya de lo técnico.