Lean tools are processes and strategies used to identify and fix problems in production to increase efficiency and minimize waste. Different types of tools, such as Six Sigma and activity-based assessment, can be used to evaluate and improve production flow, product profitability, and physical objects used in the process.
Sometimes referred to as lean manufacturing tools, lean tools are processes and strategies that are used to identify problems in the production of goods or services and fix those problems so as to increase the efficiency of the operation. A variety of tools are used to evaluate situations and respond to them in order to minimize waste and pave the way for the greatest profit. Businesses of all sizes can adapt these basic tools to any situation, whether they focus on a production line or the way tasks run in an office.
Lean manufacturing in general has to do with making sure that no resources are wasted as quality products are created for eventual sale to consumers. Any action or set of circumstances that involves the use of resources in ways that do not help achieve this ultimate goal are considered wasteful and should be eliminated from the operation. From this point of view, lean tools allow you to continuously evaluate what is happening with the company and make sure that nothing is wasted.
Different types of lean tools have to do with identifying any reasons for defects in the quality of the products produced and ridding the process of those reasons as a way to offer a better product to consumers. An example would be an approach known as Six Sigma, where the use of a combination of statistical data, quality control measures that address employee safety, cycle time, product delivery, and even material quality prime. Originally developed and employed by Motorola, the Six Sigma approach has both supporters and detractors within the business community, with some considering it an excellent tool in lean manufacturing, and others believing it is too structured to allow the approach to be adapted certain situations.
The range of lean tools is extremely broad and allows you to use different combinations of strategies to achieve the desired effect. In some cases, the tools may focus on organizing the production flow for greater benefit by identifying where the flow is working well and where it can be improved by rearranging the placement of production machinery.
Other times, refining the process involves using a tool known as activity-based assessment. This and other types of lean tools take a close look at the performance achieved by different products offered within an overall product line. By carefully examining both the cost and return associated with manufacturing and selling a particular product, it is possible to determine whether that product is profitable and whether it could be made more profitable by addressing a few identified issues with the manufacturing process. Streamlined tools such as activity-based costing can also help determine whether output should be withheld in favor of expanding production of more in-demand goods, assuming yield is low and demand is low.
Some lean tools aren’t strategies, but are physical objects used as part of a process. Labels used in color coding records or identification steps in a manufacturing process can be identified as tools. Containers that are clear or designed to stack securely are also examples of lean tools. As long as the item in question helps the business produce a quality product at a reasonable price and ultimately provides customer satisfaction, the item is likely to be a lean tool of some sort.
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