What's your process for streamlining production?

1 Assess your current state

The first step to streamlining your production is to assess your current state and identify the sources of waste and inefficiency in your process. You can use tools such as value stream mapping, 5S, and gemba walks to map out your process, organize your workspace, and observe the actual conditions on the shop floor. By doing this, you can pinpoint the areas where you can reduce waste, such as overproduction, waiting, defects, inventory, motion, transportation, and overprocessing.

2 Implement continuous improvement

The second step to streamlining your production is to implement continuous improvement, a culture of constantly seeking ways to improve your process and eliminate waste. You can use tools such as PDCA (plan-do-check-act), kaizen, and poka-yoke to test and implement changes, monitor and measure their effects, and prevent errors and defects. By doing this, you can increase your productivity, quality, and customer satisfaction.

3 Apply pull systems and flow

The third step to streamlining your production is to apply pull systems and flow, a way of managing your production based on the actual demand from your customers and the smooth movement of materials and information through your process. You can use tools such as kanban, heijunka, and takt time to control your inventory levels, balance your workload, and synchronize your production pace. By doing this, you can reduce your lead times, inventory costs, and waste.

4 Optimize your layout and equipment

The fourth step to streamlining your production is to optimize your layout and equipment, a way of arranging your physical space and resources to facilitate the flow of your process and eliminate waste. You can use tools such as cellular manufacturing, SMED (single-minute exchange of die), and TPM (total productive maintenance) to group your machines and workers by product or process, reduce your setup times, and maintain your equipment performance. By doing this, you can improve your flexibility, efficiency, and reliability.

5 Empower your people and teams

The fifth step to streamlining your production is to empower your people and teams, a way of engaging and developing your workforce to participate in the improvement of your process and the delivery of value to your customers. You can use tools such as hoshin kanri, visual management, and standard work to align your goals and strategies, communicate and share information, and establish and follow best practices. By doing this, you can enhance your collaboration, innovation, and morale.

6 Seek external feedback and benchmarking

The sixth step to streamlining your production is to seek external feedback and benchmarking, a way of learning from your customers and competitors to identify the gaps and opportunities in your process and performance. You can use tools such as voice of the customer, quality function deployment, and SWOT analysis to understand your customer needs and expectations, translate them into your product and process requirements, and assess your strengths, weaknesses, opportunities, and threats. By doing this, you can increase your customer loyalty, market share, and competitiveness.

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?