Lean is a well-known concept in the world of continuous improvement. The result is "sustainable improvement of your organisation, enthusiasm for work and elimination of losses." The Lean Manufacturing philosophy will work towards continuous improvement of (work) processes, eliminating losses. Lean originated in the automotive industry and approaches the supply chain from raw materials to customers. Lean Manufacturing is based on 5 principles in which the process can be improved:

1. Specify customer value
2. Analyse the value stream
3. Create flow (process & employees)
4. Organise the process from back to front, starting with the customer.
5. Aim for perfection
   
   

Lean Manufacturing puts the customer first to realise maximum customer value. Losses from the value stream are addressed, leaving only value-added activities.

This is done by allowing employees to develop so that they can solve their own problems.

Experience shows that companies that successfully implement Lean can save a lot of delivery times and costs. All processes are designed so that the right materials are delivered at the right place, right time and in the right quantity. 

In a Lean culture, the customer desire is always central, there is leadership with a clear vision, a common standard, continuous improvement and feedback is part of daily work, and a high degree of transparency. It encourages employees to become action-oriented and keep focus on the process.

Structure in the workplace in 5 steps

Implementing 5S on the shop floor has the biggest goal of increasing productivity and effectiveness by creating and maintaining the workplace.

The search for tools and resources is removed, and a visual place is created for everything. Employee productivity increases, more production is possible because the right tools are within reach. In a clean and tidy environment, it is easier to think clearly and sharply. By implementing 5S method, we can offer production staff peace and structure on the shop floor.

The 5S system consists of 5 phases:
Seiri - Separating - Determining what is needed and what can go away.
Seiton - Arrange - Tools logical and easy for use arrange.
Seiso - Cleaning - Clean up the environment and visualise the workplace.
Seiketsu - Standardise - Defining the working method for the workplace.
Shitsuke - Hold firm - Making sure everyone sticks to the agreements.

Building blocks of a structured workplace
Implementing 5S delivers an orderly and structured workplace. But when it comes down to it, it delivers much more. For instance, lines can be applied on the shop floor, shadow boards hung, 5S labels added, safety markings created, and 5S audit boards installed. The work environment actually gets a total upgrade.

Read in "Success Stories" how this 5S was implemented at Dragon Plastics.

Improve machine effectiveness

Overall Equipment Effectiveness provides insight into where the machine's losses are and thus shows the potential for improvement. OEE is basically a tool by and for the operators at the machine. To identify losses here and then eliminate them. OEE is calculated on the basis of 3 categories:

1. Availability
2. Performance
3. Quality
   
   

Ownership
The OEE technique reveals where machine losses are and gives operators ownership of their machine. All this to improve machine effectiveness. Operators are trained to take more responsibility over rejects or losses and learn about the machine technically and process-wise, leading to a desire to produce as effectively as possible.

Machine reliability
Increasing machine reliability will eliminate the source causes of all kinds of losses. Thus, unplanned breakdowns will give way to planned maintenance. Thus, production will not be at a standstill unexpectedly.