How it Works

Lean manufacturing is a collection of practices and tools that companies use to improve their efficiency and profitability. It’s a continuous improvement practice meaning lean manufacturers will always be looking for ways to make their operations better.

In Lean manufacturing, tools are used as a way to standardize efforts. They also help manufacturers create and maintain consistency across their business operations by eliminating wasteful processes and implementing Lean principles where they’re needed most.

Lean tools can be highly effective in helping manufacturers cut costs, streamline operations, reduce downtime and improve quality control in a variety of ways.

Why Lean Manufacturing?

Lean manufacturing is a manufacturing method that focuses on reducing costs through the elimination of waste, which in turn results in improved profitability for manufacturers. The practice can be applied to any company across all industries.

Lean manufacturing saves you money in a number of ways. It eliminates the need for excess inventory, reduces the total time it takes to get products from suppliers to warehouses, removes unnecessary steps from manufacturing processes, and increases transparency by improving visibility into operations.

Learn all about Lean manufacturing practices here.

The Best Tools for Lean Manufacturers

1. OEE Systems

OEE stands for Overall Equipment Effectiveness, and it’s a Lean tool that uses data to help manufacturers understand what’s going on in their plant. The system enables manufacturers to monitor the performance of their equipment from one central location.

OEE systems provide real-time communication, performance monitoring, and reporting analyses to give you insight into what’s going on with your equipment.

2. Wireless Sensor Networks

Wireless sensor networks use technology to monitor equipment in real-time. They collect information about the performance of different types of equipment, allowing manufacturers to improve their processes.

Wireless sensor networks create a Lean manufacturing environment that enables manufacturers to continue Lean practices during plant downtimes or plant shutdowns.

3. Smart Andon Systems

The practice of just-in-time manufacturing involves producing products only when they’re needed. This concept relies on the manufacturing tool called an Andon, which encompases the idea that workers request assistance and let everyone in the factory know that there’s a problem with the production line.

Smart Andon systems create Lean manufacturing environments by automatically stopping the production line when problems are detected. Calling for help and getting resources to a line by increasing accountability will reduce downtime and increase productivity.  Tracking and acknowledging response times is a recommended part of a complete Andon system.  

4. Cloud-Based Manufacturing Software

Cloud-based software systems provide manufacturers with the Lean manufacturing tools they need to manage their operations from anywhere using any device.

Manufacturers can upload data to cloud-based systems, which creates Lean manufacturing environments that help them understand what’s happening with their operations at any time, from anywhere.

5. Visual Management Solutions

Visual management solutions provide immediate visual status on production output and display the current issues impacting production. One screen can show the whole picture of your production floor, allowing you to get a comprehensive view of your production processes.

Visual manufacturing tools allow manufacturers to quickly prioritize issues that need immediate attention.

Lean manufacturing tools allow your business to run efficiently without extra effort from you. VersaCall offers a wide variety of services to help your manufacturing business run smoothly.

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Productivity is the measure of how much output a worker produces in a given amount of time. The more productive a worker is, the more they can produce in a shift, and the more efficient the factory as a whole becomes.

There are many things that can slow the production process in manufacturing, and it’s critical to avoid them if you want to be productive. Here are the top 10:

1. Lack of Standardization

When different parts are made by different people and to various specifications, it can be difficult to achieve consistent quality. This can lead to defects and rework, which lower productivity. A lack of standardization can also make it difficult to automate manufacturing processes and to track inventory.

– To avoid this pitfall, develop standardized processes and specifications, and make sure that everyone on the production floor understands and follows them.

2. Lack of Training and Knowledge

If employees don’t have the training and knowledge to do their jobs properly, it can lead to defects and wasted time and money. This is especially true when new systems and software are integrated into your operations and training may need to be updated.

– To avoid this, make sure that everyone who works in the plant is properly trained and has the knowledge they need to do their jobs effectively. When changes are introduced to your processes, provide updated training.

3. Defective Parts

Defective parts can cause a number of problems in a manufacturing plant, including rework, scrapped product, and downtime. All of these reduce productivity and profitability.

– To avoid defective parts issues, make sure that quality control is a top priority in the plant, and invest in quality assurance measures such as good manufacturing practices (GMP) and statistical process control (SPC).

4. Poor Quality Control

As mentioned, defective parts can come as a result of poor quality control. Poor quality control can also lead to customer complaints and loss of business.

– To avoid quality control issues, implement manufacturing technology that can improve quality control through automation. Robust quality control systems can help avoid loss of scrapped products and valuable customers.

5. Poor Equipment Maintenance

If your equipment is not properly maintained, it can lead to unnecessary downtime. Equipment and software not only needs to be updated regularly, it also needs to be: protected from cybersecurity incidents; seamlessly integrated with your other software and hardware systems; and replaced when necessary.

– To avoid this pitfall, make sure that the equipment is kept up to date. Keep track of all your devices and which users are authorized to use it. Hire a manufacturing technology expert to make sure your systems are properly integrated and protected.

8. Poor Inventory Management

In a manufacturing plant, inventory can take up a lot of space, searching through inventory can take up a lot of time, and it can be easy to lose track of what you have. This can result in wasted time and money looking for parts that are not in stock and having to order them using costly rush shipping methods from suppliers.

– To avoid inventory issues, develop and implement an effective system for tracking inventory and make sure that everyone on the production floor is aware of it. Keep a close eye on inventory levels and reorder parts only when necessary.

9. Lack of Standardized Packaging

Lack of standardized packaging can cause major confusion in the warehouse and on the production line. When packaging isn’t consistent, products can get mixed up, messed up, and improperly sent to clients.

– To avoid this issue, create consistent packaging guidelines across all departments. Ensure your employees understand what the packaging labels mean and the issues that come from improper packaging.

10. Lack of Communication and Collaboration

Poor communication across your production plant can lead to major issues. For example, if marketing sends out specifications for mass customization without coordinating with production, it can cause delays in getting the product to market.

– To avoid communication issues, Encourage communication and collaboration between departments.Make sure that everyone in the company can be notified in real-time of changes that need to be made or updates that need to occur, as well as how their department contributes to it.IMplementing technology such as Andon systems can notify you as soon as there is a problem or disruption on the production floor. 

In order to ensure that your manufacturing plant is productive, it’s important to avoid these common issues that manufacturing facilities are often faced with.. By implementing the right measures and systems, you can keep your plant running smoothly and increase productivity.

The manufacturing industry often utilizes expensive and specialized machines to perform  operations for production. These machines require both preventative maintenance and on the spot maintenance, which is not possible without a straightforward method of evaluating the serviceability of a machine.

One of the best methods of assessing and maintaining a large facility is machine monitoring. Apart from helping you know how the device operates in real-time, machine monitoring allows for immediate action to improve a machine’s efficiency.

What Is Machine Monitoring?

Machine monitoring is a process that involves the extraction, storage, and display of machine data in an industrial context. A machine monitoring system is a reliable, scalable system that turns manufacturing data into valuable real-time insights, providing better visibility and highlighting targeted improvements. 

You can use machine monitoring to make significant improvements and maximize your company’s efficiency and profitability. It works by installing a machine monitoring system consisting of hardware and software tools for processing raw information coming from machines when in use.

A typical monitoring system includes the following:

• Industrial sensors
• Monitoring and analysis software
• Touchscreen interfaces
• IIoT platforms
• Frontline operations platform

Machine monitoring systems are used on a variety of industrial machines, including electric motors, pumps, compressors, heat exchangers, piping and steam boilers, and additional machinery.

Machine Monitoring Best Practices

Machine monitoring is easier to implement than you might think. Most modern systems come with plug-and-play software that requires an internet connection. Once you find the right machine monitoring system provider, here are the simple steps you should take:

Assess Your Current Needs and Capabilities

Start by assessing the number of machines you currently use on your shop floor, output diversity, production schedules, whether analog or digital, and operators’ importance.

You also need to check the kind of protocols the machine uses and whether the protocols are deprecated or proprietary. Finally, check your infrastructure and security requirements to make sure your standards are up-to-date. 

Establish Your Machine’s Working Condition

Before you implement a machine monitoring system, you need to establish its current working condition. Some of the data points to assess may include the production capacity during uptime and downtime. For example, you could discover that your current uptime was only 60% when you thought it to be 80%.

Account for the Operator

Since machines do not operate in isolation, it is essential to consider the impact of the operator’s work on a machine’s performance. You could require your machine operators to enter reasons for downtime, process completions, and log errors at the source.

Applications can record the operator on duty, the machine program running at a particular time, and the operational hours of a machine.

Design Applications Unique to Your Operations

Once you have collected enough human and machine data, you can design unique applications to track production volume and quality throughout the value system. You can then scale the program to additional machines or the entire manufacturing plant.

Conclusion

Machine monitoring is essential in collecting and analyzing real-time data on your machine’s operation and condition. It can help catch and resolve machine faults quickly, improving productivity and efficiency.

To learn more about machine monitoring and how it can improve your manufacturing business, contact us today.

There are several manufacturing methods that help manufacturing companies limit their waste, enhance productivity, and reach their continuous improvement goals. One of the most popular methods is Lean Manufacturing.

What Is Lean Manufacturing?

Lean Manufacturing is a production method that was created in the 1990’s and is used by businesses to improve their efficiency. It includes principles that are generally applied to an entire business/organization, such as logistics, supply chain management, lean planning and lean enterprises. The goal of this method is to meet customer demand as quickly as possible with minimal waste.

How Do Lean Methods Improve Efficiency?

Lean Manufacturing helps manufacturers reduce costs by reducing or eliminating unnecessary movements and processes, whether those activities are performed by workers or machines.

For example, manufacturers may introduce an Andon system to notify personnel more quickly of production floor disruptions, or a scheduling system to limit work-in-progress inventory and make sure that workers only perform the tasks that add value to the business.

Lean Manufacturing can help to improve efficiency by eliminating waste in an organization’s processes. It also helps businesses develop lean thinking cultures where employees are encouraged to take initiative and make improvements based on their observations and experiences.

How Does Lean Manufacturing Complement Continuous Improvement?

Continuous improvement focuses on an organization’s waste and productivity levels and is one of the main ways to improve efficiency. Manufacturing firms constantly modify their continuous improvement goals to increase profits.

Making lean improvements in the workplace by eliminating unnecessary actions, reducing excess inventory and overproduction, and simplifying processes are a few ways to reach continuous improvement goals.

There are also some specific practices within Lean Manufacturing that greatly complement continuous improvement.

Lean Thinking: Lean thinking is the framework of Lean Manufacturing applied to an entire business. It aims to develop innovative ways of thinking about the best and most efficient ways to deliver value to consumers while eliminating waste.

Lean Enterprise: Lean enterprise is Lean Manufacturing applied across a broad value chain. It is a production principle that operates on the basis that any aspect of an enterprise that does not directly benefit the product being made is unnecessary.

These two principles help eliminate waste and guide continuous improvement towards more specific, achievable goals. As continuous improvement becomes more attainable, efficiency increases.

What Types of Lean Technologies Are There?

There are several technologies that help to eliminate waste and simplify processes.

One of the most common lean technologies is a smart Andon system, which immediately notifies production personnel when there is an issue on the production floor. They can also predict when production equipment may need repairs or upgrades.

Another common technology is an OEE system, which is a hardware and software solution that increases output and minimizes downtime, allowing manufacturers to increase efficiency. OEE solutions provide rapid communication across your production floor, as well as real-time monitoring and advanced reporting.

Manufacturers may also use visual management solutions to get immediate visual status on production output and display any issues that may be impacting production speed or efficiency.

The Bottom Line

Lean Manufacturing methods and technologies can help your business improve efficiency. Whether you need to reduce waste, increase output, or enhance your continuous improvement goals, Lean Manufacturing is a great way to address your needs.

To learn more about VersaCall’s Lean Manufacturing systems, contact our experts today.

No matter what industry your business is in, efficiency is an essential aspect of business growth.  An efficient manufacturing process plays a crucial role in improving your overall business performance and helps you meet your goals. 

Manufacturing efficiently also reduces environmental impacts, increases product quality, and builds your company’s image. Here are the best ways to increase efficiency in your manufacturing business.

Minimize Material Waste

Waste in the manufacturing industry can include energy consumption, employee hours, space, and materials. Among these, material waste is especially costly, and you should strive to reduce it in whatever ways possible. Some methods for reducing waste include: 

Recycling Scrap

You can turn waste into profits by selling recycled materials to factories that can utilize them or reworking waste materials  in your manufacturing process.

Concentrating on Design

You may realize working with a specific design will help you use less material from the onset. Processes like a design for manufacturability (DFM) can help minimize waste by thoughtfully designing parts.

Optimizing Processes to Utilize the Available Materials

If the maximum amount of material can be converted to a usable part rather than discarded as waste, it can substantially reduce manufacturing costs.

Train Your Employees Regularly

In this age of rapid technology advances, updated manufacturing processes and equipment upgrades can add new challenges to employee efficiency. Regular training will help your staff stay up-to-date with changes in the methods and familiarize them with the new equipment while observing the necessary safety measures.

When your staff is knowledgeable about the manufacturing stages, it will help maintain safety and streamline the manufacturing process. Also, it will be easy to substitute people to offer relief without affecting day-to-day activities. 

Update Processes and Technology

As new technology trends emerge, you will need to update your processes and adopt technological advancements to maximize your output. With methodologies like lean manufacturing, you have the opportunity to use various tools that help  improve manufacturing efficiency by reducing waste.

Deploying new software solutions and automation tools will help you schedule, monitor workflow, reduce errors, and improve production speed. Although the initial purchasing cost of improved equipment and tools may be high, the long-term benefits are worthwhile.

Organize Your Workplace

A well-organized workspace makes efficiency simple. Ensure you remove clutter and organize each area to determine what works best for you. Organize your storage in a way that all materials are visible and easily accessible. Implementing a 5s system, or a similar process, will save time to look for tools, materials, parts, instructions and equipment.

Also, be sure to remove all unneeded tools and waste from the floor to help you create a smoother workflow for components, products and people. A well-organized storage will help you know when your stock is running out and prevent downtime.

Bottom Line

An efficient manufacturing process has a significant impact on your end product. Versacall offers a variety of cost-effective manufacturing systems and solutions to help you track products accurately, reduce downtime, and ease management-employee communication. If you are looking for strategies and techniques to improve productivity, contact us today for a free demo.